U.S. patent application number 15/011137 was filed with the patent office on 2017-08-03 for light fixture with removable light cartridge.
The applicant listed for this patent is Hunter Industries, Inc.. Invention is credited to Thomas E. Veloskey.
Application Number | 20170219188 15/011137 |
Document ID | / |
Family ID | 59385488 |
Filed Date | 2017-08-03 |
United States Patent
Application |
20170219188 |
Kind Code |
A1 |
Veloskey; Thomas E. |
August 3, 2017 |
LIGHT FIXTURE WITH REMOVABLE LIGHT CARTRIDGE
Abstract
A light fixture can include a light housing and a light
cartridge. The light cartridge can be configured to releasably
and/or electrically connect to a portion of the light housing. In
some embodiments, the light cartridge includes a collar movably
connected to the cartridge and configured to rotate with respect to
the cartridge. Rotation of the collar can facilitate attachment
and/or release of the cartridge from the light housing. In some
cases, the cartridge includes a releasable driver, one or more
lenses, one or more beam reflectors, one or more diffusers, and/or
other electrical and optical components.
Inventors: |
Veloskey; Thomas E.; (San
Marcos, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hunter Industries, Inc. |
San Marcos |
CA |
US |
|
|
Family ID: |
59385488 |
Appl. No.: |
15/011137 |
Filed: |
January 29, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21V 29/507 20150115;
H05B 47/19 20200101; F21V 21/30 20130101; F21V 29/74 20150115; F21S
8/022 20130101; F21V 7/00 20130101; F21V 19/02 20130101; F21V 17/02
20130101; F21Y 2115/10 20160801; F21V 3/00 20130101; F21V 31/005
20130101; F21V 21/14 20130101; F21V 23/06 20130101; F21W 2131/10
20130101; F21V 29/70 20150115; F21V 23/003 20130101 |
International
Class: |
F21V 19/02 20060101
F21V019/02; F21V 17/02 20060101 F21V017/02; F21V 3/00 20060101
F21V003/00; F21V 7/00 20060101 F21V007/00; F21V 29/74 20060101
F21V029/74; H05B 37/02 20060101 H05B037/02; F21V 23/00 20060101
F21V023/00; F21V 23/06 20060101 F21V023/06; F21V 31/00 20060101
F21V031/00 |
Claims
1. A light fixture comprising: a light housing having: a first end;
a second end; an opening at the first end; a light housing axis
extending through the first and second ends; and at least one
sidewall defining a light housing interior; and a light cartridge
configured to releasably and electrically connect to a portion of
the light housing, the light cartridge having: a cartridge body
having: a body axis; a first end; and a second end spaced from the
first end along the body axis; a collar moveably connected to the
first end of the cartridge body; an electrical connector configured
to releasably and electrically connect with a source of electric
power; and a light element operably connected to the electrical
connector and configured to direct light out of the opening of the
light housing when the light cartridge is connected to the light
housing; wherein the light cartridge is configured to: transition
between a connected position and a released position with respect
to the light housing; transition from the connected position to the
released position via rotation of the collar about the light
housing axis, followed by translation away from the second end of
the light housing toward the first end of the light housing; and
transition from the released position to the connected position via
translation through the opening of the light housing toward the
second end of the light housing, followed by rotation about of the
collar the light housing axis.
2. The light fixture of claim 1, wherein the light cartridge is
configured to transition between the connected and released
positions without the use of tools.
3. The light fixture of claim 1, comprising a handle connected to
the collar.
4. The light fixture of claim 1, wherein the collar is configured
to rotate with respect to the cartridge body.
5. The light fixture of claim 3, wherein the handle comprises a
gripping portion and a pair of tracks connected to the gripping
portion.
6. The light fixture of claim 5, wherein the gripping portion has a
first end and a second end and an arcuate body extending between
the first and second ends, the arcuate body having a concave side
and a convex side opposite the concave side,
7. The light fixture of claim 5, wherein each of the pair of tracks
has an arcuate shape, and wherein the tracks are configured to move
in an arcuate path as the handle is transitioned between an
actuation position and a closed position.
8. The light fixture of claim 3, wherein the handle is configured
to rotate about a first axis of rotation when the handle
transitions between an actuation position and a closed position,
and wherein the handle is configured to rotate about the light
housing axis when the light cartridge transitions between the
connected and released positions.
9. The light fixture of claim 8, wherein the first axis of rotation
is perpendicular to the body axis of the cartridge body.
10. A light fixture comprising: a light housing having an opened
end; and a light cartridge configured to releasably and
electrically connect to a portion of the light housing, the light
cartridge having: a cartridge body; a collar rotatably connected to
the cartridge body; an electrical connector configured to
releasably and electrically connect with a source of electric
power; and a light element operably connected to the electrical
connector and configured to direct light out of the opened end of
the light housing when the light cartridge is connected to the
light housing; wherein the collar is configured to: rotate between
a first position and a second position with respect to the
cartridge body.
11. The light fixture of claim 10, wherein the light cartridge has
a body axis and includes a locking tab extending away from the body
axis, wherein the light housing includes a tab slot, and wherein
the locking tab is configured to couple with and move with respect
to the tab slot when the light cartridge is transitioned between a
connection with and disconnection from the light housing.
12. The light fixture of claim 11, wherein the tab slot has a
helical shape configured to move the light cartridge toward an end
of the light housing opposite the opened end as the collar is
rotated to the second position when the locking tab is positioned
within the tab slot.
13. The light fixture of claim 11, wherein the locking tab is
positioned on the collar.
14. The light fixture of claim 11, wherein the locking tab is
positioned closer to the light element than to an end of the light
cartridge opposite the light element.
15. (canceled)
16. (canceled)
17. The light fixture of claim 10, wherein an electrical connection
between the light cartridge and the light housing is engaged as the
collar is rotated to the second position when the light cartridge
is positioned within the light housing, and wherein the electrical
connection between the light cartridge and the light housing is
disengaged as the light cartridge is rotated to the first position
when the light cartridge is electrically connected to the light
housing.
18. A light fixture comprising: a light housing having: a first
end; a second end; an opening at the first end; a light housing
axis extending through the first and second ends; and at least one
sidewall defining a light housing interior; a light cartridge
configured to releasably and electrically connect to a portion of
the light housing, the light cartridge having: a cartridge body; a
collar moveably connected to the first end of the cartridge body
and configured to transition between an actuation position and a
closed position; and a light element configured to direct light out
of the opening of the light housing when the light cartridge is
connected to the light housing; and a light cover configured to
removably connect to the first end of the light housing.
19. The light fixture of claim 18, wherein the light cover
comprises a cover portion and a mating portion extending from the
cover portion toward the second end of the light housing when the
light cover is connected to the light housing, wherein the mating
portion of the light cover includes at least one seal configured to
form a seal between the mating portion and a portion of the light
housing, and wherein the seal between the mating portion of the
light cover and the portion of the light housing inhibits or
prevents moisture ingress past the light cover to the light
cartridge.
20. The light fixture of claim 18, wherein the light cover includes
an aperture configured to receive a fastener, wherein the light
housing includes a fastener recess aligned with the aperture of the
light cover when the light cover is connected to the first end of
the light housing, and wherein light cover is configured to be
removable from the light housing by hand after the fastener is
removed from the fastener recess.
21. The light fixture of claim 18, wherein, when the light cover is
installed on the light housing: the light cover includes a lens
seat and a lens positioned within the lens seat, the lens having: a
front face; a back face opposite the front face and positioned
closer to the second end of the light housing; a first end
extending between the front and back faces; and a second end
extending between the front and back faces opposite the first end;
the first end of the lens is positioned closer to the second end of
the light housing than the second end of the lens; at least a
portion of the light cover positioned beyond the first end of the
lens with respect to the second end of the lens is positioned
closer to the second end of the light housing than any portion of
the front face of the lens; and the portion of the front face of
the lens closest to the second end of the light housing is visible
from at least one direction perpendicular to the light housing
axis.
22. (canceled)
23. The light fixture of claim 21, wherein the first end of the
lens is positioned beneath the any other portion of the lens when
the first end of the light housing is positioned above the second
end of the light housing, and when the light housing axis is within
10.degree. of vertical.
24. The light fixture of claim 23, wherein the light cover and lens
are configured to direct water away from the lens and out from the
light cover when the first end of the light housing is positioned
above the second end of the light housing and the light housing
axis is within 10.degree. of vertical.
25. The light fixture of claim 18, wherein, when the light cover is
installed on the light housing: the light cover includes a lens
seat and a lens positioned within the lens seat; wherein, when the
light cover is positioned above the second end of the light housing
and the light housing axis is within 10.degree. of vertical, the
light cover is configured to inhibit accumulation of water on the
lens and direct all water off of the lens and out from the light
cover.
26. The light fixture of claim 18, wherein the light cover includes
a shroud.
27-68. (canceled)
Description
BACKGROUND
[0001] Technical Field
[0002] The present invention relates to light fixtures, and more
particularly, light fixtures designed for outdoor installation.
[0003] Description of the Related Art
[0004] Outdoor lighting is popular for security, aesthetic, safety,
and other reasons. For many years outdoor landscape light fixtures
have incorporated incandescent light bulbs. Recent advances in
light emitting diode (LED) technology have led to an increased
demand for improved landscape light fixtures that utilize more
reliable and more energy efficient high intensity LEDs.
[0005] Various types of commercial landscape light fixtures are
available to meet the particular needs of residential or commercial
properties. These include path, down, deck, tree, spot, spread, and
security light fixtures.
SUMMARY
[0006] In many installations and circumstances, it is desirable to
utilize a light fixture that is reliable and easy to repair. This
can be especially true in installation environments subject to rain
or other environmental hazards. In some cases, a reliable and
easy-to-repair light fixture can include a light housing configured
to receive a light cartridge. The light cartridge can be
constructed to include many or most of the lighting and/or
electrical components of the light fixture. In some cases, the
light cartridge is interchangeable with other light cartridges
(e.g., replacement light cartridges and/or light cartridges having
varying lighting/power/operable features). The light cartridge can
include a handle or other structure configured to facilitate easy
installation and removal of the cartridge from the light housing.
In some embodiments, the handle or other structure is moveable with
respect to a body portion of the light cartridge.
[0007] According to some variants, a light fixture includes a light
housing. The light housing can have a first end; a second end; an
opening at the first end; a light housing axis extending through
the first and second ends; and/or at least one sidewall defining a
light housing interior. The light fixture can include a light
cartridge. The light cartridge can be configured to releasably and
electrically connect to a portion of the light housing. In some
embodiments, the light cartridge has a cartridge body having: a
body axis; a first end; and/or a second end spaced from the first
end along the body axis. The cartridge can include a collar
moveably connected to the first end of the cartridge body; an
electrical connector configured to releasably and electrically
connect with a source of electric power; and/or a light element
operably connected to the electrical connector and configured to
direct light out of the opening of the light housing when the light
cartridge is connected to the light housing. In some embodiments,
the light cartridge is configured to: transition between a
connected position and a released position with respect to the
light housing; transition from the connected position to the
released position via rotation of the collar about the light
housing axis, followed by translation away from the second end of
the light housing toward the first end of the light housing; and/or
transition from the released position to the connected position via
translation through the opening of the light housing toward the
second end of the light housing, followed by rotation about of the
collar the light housing axis.
[0008] In some embodiments, the light cartridge is configured to
transition between the connected and released positions without the
use of tools.
[0009] In some embodiments, the light fixture includes a handle
connected to the collar.
[0010] In some embodiments, the collar is configured to rotate with
respect to the cartridge body.
[0011] In some embodiments, the handle comprises a gripping portion
and a pair of tracks connected to the gripping portion.
[0012] In some embodiments, the gripping portion has a first end
and a second end and an arcuate body extending between the first
and second ends, the arcuate body having a concave side and a
convex side opposite the concave side,
[0013] In some embodiments, each of the pair of tracks has an
arcuate shape. In some embodiments, the tracks are configured to
move in an arcuate path as the handle is transitioned between an
actuation position and a closed position.
[0014] In some embodiments, the handle is configured to rotate
about a first axis of rotation when the handle transitions between
an actuation position and a closed position.
[0015] In some embodiments, the handle is configured to rotate
about the light housing axis when the light cartridge transitions
between the connected and released positions.
[0016] In some embodiments, the first axis of rotation is
perpendicular to the body axis of the cartridge body.
[0017] In some embodiments, the light cartridge comprises a driver
removably connected to the cartridge body and electrically
connected to the light element.
[0018] According to some variants, a light fixture can include a
light housing having an opened end; and/or a light cartridge
configured to releasably and electrically connect to a portion of
the light housing. The light cartridge can include a cartridge
body; a collar rotatably connected to the cartridge body; an
electrical connector configured to releasably and electrically
connect with a source of electric power; and/or a light element
operably connected to the electrical connector and configured to
direct light out of the opened end of the light housing when the
light cartridge is connected to the light housing. In some
embodiments, the collar is configured to rotate between a first
position and a second position with respect to the cartridge
body.
[0019] In some embodiments, the light cartridge has a body axis and
includes a locking tab extending away from the body axis. In some
embodiments, the light housing includes a tab slot. In some
embodiments, the locking tab is configured to couple with and move
with respect to the tab slot when the light cartridge is
transitioned between a connection with and disconnection from the
light housing.
[0020] In some embodiments, the tab slot has a helical shape
configured to move the light cartridge toward an end of the light
housing opposite the opened end as the collar is rotated to the
second position when the locking tab is positioned within the tab
slot.
[0021] In some embodiments, the locking tab is positioned on the
collar.
[0022] In some embodiments, the locking tab is positioned closer to
the light element than to an end of the light cartridge opposite
the light element.
[0023] In some embodiments, the light fixture includes one or more
thermal pads positioned on the light cartridge and configured to
transfer heat from the light cartridge to the light housing.
[0024] In some embodiments, transition of the light cartridge to
the connected position compresses the one or more thermal pads, and
the one or more thermal pads have increased heat conduction
properties when compressed.
[0025] In some embodiments, an electrical connection between the
light cartridge and the light housing is engaged as the collar is
rotated to the second position when the light cartridge is
positioned within the light housing. In some embodiments, the
electrical connection between the light cartridge and the light
housing is disengaged as the light cartridge is rotated to the
first position when the light cartridge is electrically connected
to the light housing.
[0026] In some embodiments, the light cartridge comprises a driver
removably connected to the cartridge body and electrically
connected to the light element.
[0027] According to some variants, a light fixture can include a
light housing. The light housing can have: a first end; a second
end; an opening at the first end; a light housing axis extending
through the first and second ends; and/or at least one sidewall
defining a light housing interior. In some embodiments, the light
fixture includes a light cartridge configured to releasably and
electrically connect to a portion of the light housing. The light
cartridge can include a cartridge body; a collar moveably connected
to the first end of the cartridge body and configured to transition
between an actuation position and a closed position; and/or a light
element configured to direct light out of the opening of the light
housing when the light cartridge is connected to the light housing.
In some embodiments, the light fixture includes a light cover
configured to removably connect to the first end of the light
housing.
[0028] In some embodiments, the light cover comprises a cover
portion and a mating portion extending from the cover portion
toward the second end of the light housing when the light cover is
connected to the light housing. In some embodiments, the mating
portion of the light cover includes at least one seal configured to
form a seal between the mating portion and a portion of the light
housing. In some embodiments, the seal between the mating portion
of the light cover and the portion of the light housing inhibits or
prevents moisture ingress past the light cover to the light
cartridge.
[0029] In some embodiments, the light cover includes an aperture
configured to receive a fastener. In some embodiments, the light
housing includes a fastener recess aligned with the aperture of the
light cover when the light cover is connected to the first end of
the light housing. In some embodiments, light cover is configured
to be removable from the light housing by hand after the fastener
is removed from the fastener recess.
[0030] In some embodiments, when the light cover is installed on
the light housing: the light cover includes a lens seat and a lens
positioned within the lens seat. The lens can include: a front
face; a back face opposite the front face and positioned closer to
the second end of the light housing; a first end extending between
the front and back faces; and/or a second end extending between the
front and back faces opposite the first end. In some embodiments,
when the light cover is installed on the light housing, the first
end of the lens is positioned closer to the second end of the light
housing than the second end of the lens; at least a portion of the
light cover positioned beyond the first end of the lens with
respect to the second end of the lens is positioned closer to the
second end of the light housing than any portion of the front face
of the lens; and/or the portion of the front face of the lens
closest to the second end of the light housing is visible from at
least one direction perpendicular to the light housing axis.
[0031] In some embodiments, the lens is planar.
[0032] In some embodiments, the first end of the lens is positioned
beneath the any other portion of the lens when the first end of the
light housing is positioned above the second end of the light
housing, and when the light housing axis is within 10.degree. of
vertical.
[0033] In some embodiments, the light cover and lens are configured
to direct water away from the lens and out from the light cover
when the first end of the light housing is positioned above the
second end of the light housing and the light housing axis is
within 10.degree. of vertical.
[0034] In some embodiments, when the light cover is installed on
the light housing, the light cover includes a lens seat and a lens
positioned within the lens seat, and when the light cover is
positioned above the second end of the light housing and the light
housing axis is within 10.degree. of vertical, the light cover is
configured to inhibit accumulation of water on the lens and direct
all water off of the lens and out from the light cover.
[0035] In some embodiments, the light cover includes a shroud.
[0036] In some embodiments, the light fixture includes a pivot
mount rotatably connected to the light housing. In some
embodiments, the light housing is configured to rotate up to a
range of approximately 120.degree. of rotation with respect to the
pivot mount.
[0037] In some embodiments, the light fixture includes a fastener
configured to engage with the light housing and pivot mount. In
some embodiments, loosening the fastener permits rotation of the
light housing with respect to the pivot mount and tightening the
fastener rotationally locks the light housing with respect to the
pivot mount.
[0038] In some embodiments, the pivot mount includes a mount
opening. In some embodiments, the mount opening defines the only
aperture through which wires pass out from the light fixture.
[0039] In some embodiments, the light cartridge comprises a driver
removably connected to the cartridge body and electrically
connected to the light element.
[0040] In some embodiments, the light cartridge includes a clamp
configured to retain the driver in connection to the cartridge
body. In some embodiments, the clamp is configured to transition
between a retaining position in which the driver is retained in
position and a release position in which the driver may be removed
from the cartridge body.
[0041] In some embodiments, the clamp is configured to accommodate
drivers of various physical sizes.
[0042] According to some variants, a light assembly includes an
outer housing. The outer housing can include: a first end
configured to be positioned at or below a ground level or wall
surface when installed; a second end opposite the first end; and/or
an outer housing axis extending through the first and second ends
of the outer housing. The light assembly can include an inner
housing assembly. The inner housing assembly can include: a first
end; a second end; a hollow inner housing body extending between
the first and second ends of the inner housing; a light cartridge
positioned within the inner housing body and having a lighting
element configured to emit light through the second end of the
inner housing assembly; and/or a tilt assembly connected to the
inner housing body and having a user input portion configured to
receive user input. The tilt assembly can be configured to tilt the
light cartridge between a first tilt position and a second tilt
position with respect to the outer housing axis upon receipt of
user input. In some embodiments, the tilt assembly is configured to
tilt the light cartridge between the first and second tilt
positions without breaking the hermetic seal of the second end of
the inner housing.
[0043] In some embodiments, the light assembly includes a lens
assembly connected to the second end of the inner housing assembly
and configured to hermetically seal the second end of the inner
housing.
[0044] In some embodiments, the lens assembly comprises: a lens
frame configured to connect to the second end of the inner housing
assembly; a lens positioned between the lens frame and the second
end of the inner housing assembly when the lens frame is connected
to the second end of the inner housing assembly; and/or a seal
positioned between the lens and the second end of the inner housing
assembly when the lens frame is connected to the second end of the
inner housing assembly.
[0045] In some embodiments, the lens frame comprises at least one
fastener aperture configured to align with at least one fastener
aperture of the inner housing body when the lens assembly is
connected to the second end of the inner housing assembly.
[0046] In some embodiments, the tilt assembly has: an adjusting
shaft with a first end and a second end, the user input portion
positioned on the first end of the adjusting shaft; and/or a collar
adjustably connected to the adjusting shaft. In some embodiments,
the collar is configured to move toward and away from the second
end of the inner housing assembly in response to user input to the
user input portion.
[0047] In some embodiments, the tilting assembly has a bracket, the
bracket connected to the light cartridge and having at least one
rail. In some embodiments, the collar is slidably connected to the
at least one rail.
[0048] In some embodiments, the first end of the adjusting shaft is
accessible from outside of the inner housing assembly when the lens
assembly is connected to the second end of the inner housing
assembly. In some embodiments, the second end of the adjusting
shaft is positioned inside the inner housing assembly when the lens
assembly is connected to the second end of the inner housing
assembly.
[0049] In some embodiments, the adjusting shaft includes a threaded
portion between the first and second ends of the adjusting shaft.
In some embodiments, the collar includes a threaded aperture
connected to the threaded portion of the adjusting shaft.
[0050] In some embodiments, an interior of the inner housing
assembly is hermetically sealed from an exterior of the inner
housing assembly when the light assembly is assembled.
[0051] In some embodiments, the light assembly includes a strain
relief positioned through a wall of the inner housing body and
configured to permit passage of a wire through the wall of the
inner housing body in a sealed manner.
[0052] In some embodiments, the light assembly includes one or more
fasteners having heads. In some embodiments, the outer housing
includes one or more fastener apertures configured to receive the
one or more fasteners. In some embodiments, the inner housing body
includes a mating portion configured to be held between the heads
of the one or more fasteners and the outer housing body when the
one or more fasteners are received in the one or more fastener
apertures. In some embodiments, the one or more fasteners are
configured to hold the inner housing body in place with respect to
the outer housing when tightened.
[0053] In some embodiments, the inner housing assembly is
configured to transition between a first rotational position and a
second rotational position without breaking the hermetic seal on
the inner housing assembly when the one or more fasteners are
loosened.
[0054] In some embodiments, the inner housing assembly is rotatable
within the outer housing assembly without breaking the hermetic
seal on the inner housing assembly.
[0055] In some embodiments, the light assembly includes a pivot
frame positioned within the inner housing assembly and configured
to receive the light cartridge.
[0056] In some embodiments, the pivot frame comprises a sleeve
portion and at least one tilting member extending from the sleeve
portion.
[0057] In some embodiments, the at least one tilting member
comprises an arcuate surface.
[0058] In some embodiments, the inner housing body includes at
least one tilting pocket configured to receive the at least one
tilting member. In some embodiments, the at least one tilting body
has an arcuate surface configured to engage the arcuate surface of
the at least one tilting member. In some embodiments, the at least
one tilting member is configured to rotate within the tilting
pocket between a first tilt position and a second tilt
position.
[0059] In some embodiments, the at least one tilting member is
configured to rotate within the tilting pocket about a tilt axis,
and wherein the tilt axis is non-parallel to the outer housing
axis.
[0060] In some embodiments, the tilt axis is substantially
perpendicular to the outer housing axis.
[0061] In some embodiments, the at least one tilting member
comprises a first stop wall and a second stop wall. In some
embodiments, the first stop wall is configured to limit rotation of
the tilting member with respect to the tilting pocket in a first
direction and the second stop wall is configured to limit rotation
of the tilting member with respect to the tilting pocket in a
second direction.
[0062] In some embodiments, the light assembly includes at least
one pivot frame retainer connected to the inner housing body. In
some embodiments, the first stop wall is configured to abut the at
least one pivot frame retainer when the at least one tilting member
is in the first tilt position. In some embodiments, the second stop
wall is configured to abut the at least one pivot frame retainer
when the at least one tilting member is in the second tilt
position.
[0063] In some embodiments, the inner housing body comprises a tilt
housing. In some embodiments, the tilt assembly is positioned at
least partially within the tilt housing.
[0064] In some embodiments, the light assembly includes an
installation cap configured to connect to the second end of the
outer housing. In some embodiments, the installation cap includes:
a cover portion configured to cover the second end of the outer
housing when the installation cap is connected to the second end of
the outer housing; and/or a wall connected to and extending from
the cover portion is a direction away from the outer housing, the
wall configured to connect a support to suspend the outer housing
downward into an installation site.
[0065] According to some variants, a method of assembling a light
assembly can include: inserting an inner housing assembly into an
open end of an outer housing having an outer housing axis. The
inner housing assembly can be hermetically sealed and/or can
comprise a light cartridge configured to direct light through a
lens of the inner housing assembly. In some embodiments, the method
includes tilting the light cartridge with respect to the outer
housing axis without moving the hollow inner housing body of the
inner housing assembly and/or without breaking the hermetic seal of
the inner housing assembly
[0066] In some embodiments, the method includes rotating the inner
housing assembly about the outer housing assembly with respect to
the outer housing after inserting the inner housing assembly
through the open end of the outer housing and/or without breaking
the hermetic seal of the inner housing assembly.
[0067] In some embodiments, the method includes manually actuating
a user input portion of a tilt assembly within the inner housing
assembly to tilt the light cartridge with respect to the inner
housing assembly without breaking the hermetic seal of the inner
housing assembly.
[0068] In some embodiments, the method includes removing the inner
housing assembly from the outer housing and inserting a second
inner housing assembly without breaking the hermetic seal of the
inner housing assembly or a hermetic seal of the second inner
housing assembly.
[0069] In some embodiments, the method includes connecting an
installation cap to the open end of the outer housing, connecting
the installation cap to a support structure, and/or suspending the
outer housing downward into an installation site.
[0070] According to some variants, a method of assembling a light
fixture includes inserting a light cartridge through an open end of
a light fixture housing along a linear installation path to a
connected position. In some embodiments, the method includes
rotating a light cartridge collar about the installation path with
respect to both the light cartridge and the light fixture housing
after inserting the light cartridge through the open end of the
light fixture housing from an unlocked position to an unlocked
position. In some embodiments, rotation of the collar from the
unlocked position to the locked position inhibits removal of the
light cartridge from the light fixture housing along the
installation path.
[0071] In some embodiments, the method includes rotating a handle
connected to the collar about an axis of rotation non-parallel to
the installation path.
[0072] In some embodiments, the method includes aligning an
alignment structure of the light cartridge with an alignment
structure of the light fixture housing. In some embodiments,
alignment of the alignment structures of the light cartridge and
light fixture housing prevents rotation of the light cartridge with
respect to the light fixture housing as the light cartridge is
inserted through open end of the light fixture to the connected
position.
[0073] In some embodiments, movement of the light cartridge to the
connected position electrically connects the light cartridge to the
light fixture housing.
[0074] In some embodiments, the method includes connecting a light
cover to the open end of the light fixture housing to seal the open
end of the light fixture housing in a liquid-tight manner. In some
embodiments, the light cover comprises a lens through which light
from the light cartridge is configured to shine.
[0075] In some embodiments, the method includes removing a first
driver from the cartridge and connecting a second driver to the
cartridge. In some embodiments, the second driver is larger or
smaller than the first cartridge in at least one dimension.
[0076] In some embodiments, the light cartridge is inhibited from
full insertion into the light fixture housing when the collar is
not in the unlocked position as the light cartridge is inserted
through the open end of the light fixture housing.
[0077] According to some variants, a light assembly can include an
outer housing. The outer housing can have: a first end; a second
end opposite the first end; and/or an outer housing axis extending
through the first and second ends of the outer housing. In some
embodiments the light assembly includes an inner housing assembly.
The inner housing assembly can include a first end; a second end;
and/or a hollow inner housing body extending between the first and
second ends of the inner housing. In some embodiments, the light
assembly includes a light cartridge positioned within the inner
housing body and having a lighting element configured to emit light
through the second end of the inner housing assembly. In some
embodiments, the light assembly includes a lens assembly connected
to the second end of the inner housing assembly and configured to
hermetically seal the second end of the inner housing. In some
embodiments, the light assembly includes a tilt assembly connected
to the inner housing body and having a user input portion
configured to receive user input. The tilt assembly can be
configured to tilt the light cartridge between a first tilt
position and a second tilt position with respect to the outer
housing axis upon receipt of user input. In some embodiments, the
tilt assembly is configured to tilt the light cartridge between the
first and second tilt positions without breaking the hermetic seal
of the second end of the inner housing
BRIEF DESCRIPTION OF THE DRAWINGS
[0078] The present disclosure is described with reference to the
accompanying drawings, in which like reference characters reference
like elements, and wherein:
[0079] FIG. 1 illustrates a bottom perspective view of an
embodiment of a light fixture.
[0080] FIG. 2 illustrates a top perspective view of the light
fixture of FIG. 1.
[0081] FIG. 2A illustrates an exploded view of the light fixture of
FIG. 1.
[0082] FIG. 2B illustrates a front, right, and bottom side
perspective view of the light fixture of FIG. 1, wherein broken
lines are used to illustrate features of the light fixture which
may or may not form part of the design, depending on the
embodiment;
[0083] FIG. 2C illustrates a left side elevational view
thereof;
[0084] FIG. 2D illustrates a right side elevational view
thereof;
[0085] FIG. 2E illustrates a top plan view thereof;
[0086] FIG. 2F illustrates a bottom plan view thereof;
[0087] FIG. 2G illustrates a front side elevational view
thereof;
[0088] FIG. 2H illustrates a back side elevational view
thereof;
[0089] FIG. 2I illustrates a back, right, and top side perspective
view thereof and
[0090] FIG. 2J illustrates a back, right, and bottom side
perspective thereof
[0091] FIG. 2K illustrates a front, left, bottom side perspective
view of another embodiment of a light fixture , the light fixture
being identical to the light fixture of FIGS. 1-2J with the
addition of a shroud extending from the dot-dash boundary line;
and
[0092] FIG. 2L illustrates a back, right, top side perspective view
thereof.
[0093] FIG. 3 illustrates another bottom perspective view of the
light fixture of FIG. 1, wherein the mount is rotated to a second
position.
[0094] FIG. 4 illustrates a front view of the light fixture of FIG.
1.
[0095] FIG. 5 illustrates a side cross-sectional view of the light
fixture of FIG. 1 along the cut-plane 5-5 of FIG. 4.
[0096] FIG. 6 illustrates another bottom perspective view of the
light fixture of FIG. 1 having a shroud.
[0097] FIG. 7 illustrates a side cross-sectional view of the light
fixture of FIG. 1 along the cut-plane 7-7 of FIG. 3.
[0098] FIG. 8 illustrates an exploded view of the light fixture of
FIG. 1, wherein the light cover is removed.
[0099] FIG. 9 illustrates a top perspective view of the light
fixture of FIG. 1, wherein a handle of a light cartridge is in a
down position.
[0100] FIG. 10 illustrates a front perspective exploded view of the
light fixture of FIG. 1, wherein the cartridge is removed from the
light housing.
[0101] FIG. 11 illustrates a rear perspective exploded view of the
light fixture of FIG. 1, wherein the cartridge is removed from the
light housing.
[0102] FIG. 12 is a front top perspective view of an embodiment of
a light cartridge.
[0103] FIG. 13 is a both rear perspective view of the cartridge of
FIG. 12.
[0104] FIG. 14A is a front view of an embodiment of a light
housing.
[0105] FIG. 14B is a bottom cross-section view of the light housing
of FIG. 14A along the cut-plane 14B-14B of FIG. 14A.
[0106] FIG. 14C is a tilted cross-section view of the light housing
of FIG. 14A along the cut-plane 14C-14C of FIG. 14A.
[0107] FIG. 15A is a front view of another embodiment of a light
housing.
[0108] FIG. 15B is a bottom cross-section view of the light housing
of FIG. 15A along the cut-plane 15B-15B of FIG. 15A.
[0109] FIG. 15C is a close-up view of the cross-section view of
FIG. 15B.
[0110] FIG. 15D is a tilted cross-section view of the light housing
of FIG. 15A along the cut-plane 15D-15D of FIG. 15A.
[0111] FIG. 16 is a front top perspective view of the light
cartridge of FIG. 12, wherein the handle is in a second
position.
[0112] FIG. 17 is a front top perspective view of the light
cartridge of FIG. 12, wherein the collar is rotated to a second
position.
[0113] FIG. 18 is an exploded view of the light cartridge of FIG.
12.
[0114] FIG. 19A is a front view of the light fixture of FIG. 1.
[0115] FIG. 19B is a side cross-section view of the light fixture
of FIG. 1 along the cut-plane 19B-19B of FIG. 19A, wherein the
fixture includes a light unit extender.
[0116] FIG. 20 is a front top perspective view of a light cartridge
having a light unit extender.
[0117] FIG. 21 is an exploded view of the light cartridge of FIG.
16.
[0118] FIG. 22 is a rear exploded view of the light cartridge of
FIG. 12, wherein the driver and thermal pads are removed.
[0119] FIG. 23 is a front bottom perspective view of the light
cartridge of FIG. 12.
[0120] FIG. 24 is a perspective view of an in-grade light.
[0121] FIG. 25 is an exploded view of the in-grade light of FIG.
24.
[0122] FIG. 26 is a front view of the in-grade light of FIG.
24.
[0123] FIG. 27 is a side cross-section view of the in-grade light
of FIG. 24 along the cut-plane 27-27 of FIG. 26.
[0124] FIG. 28 is another exploded view of the in-grade light of
FIG. 24.
[0125] FIG. 29 is a top perspective view of the in-grade light of
FIG. 24, wherein the lens assembly is removed.
[0126] FIG. 30 is an exploded view of an inner housing assembly of
the in-grade light of FIG. 24.
[0127] FIG. 31 is a perspective view of a pivot frame of the inner
housing assembly of FIG. 30.
[0128] FIG. 32 is a side view of the pivot fame of FIG. 31.
[0129] FIG. 33 is a top perspective view of the inner housing
assembly of FIG. 30, wherein the pivot frame, cartridge, and lens
assembly are removed.
[0130] FIG. 34 is a top perspective view of the inner housing
assembly of FIG. 30, wherein the cartridge and lens assembly are
removed.
[0131] FIG. 35 is top perspective view of the inner housing
assembly of FIG. 30, wherein the lens assembly is removed
[0132] FIG. 36 is a side cross-section view of the inner housing
assembly of FIG. 30 along the cut-plane 27-27 of FIG. 26.
[0133] FIG. 37 is a side cross-section view of the inner housing
assembly of FIG. 30 along the cut-plane 27-27 of FIG. 26, wherein
the pivot frame is tilted.
[0134] FIG. 38 is a perspective view of a tilting assembly of the
in-grade light of FIG. 24.
[0135] FIG. 39 is a close-up view of cross-section view of the
inner housing assembly of FIG. 37.
[0136] FIG. 40 is a top perspective exploded view of the inner
housing assembly of FIG. 30.
[0137] FIG. 41 is a top perspective exploded view of the in-grade
light of FIG. 24, wherein the outer housing is shown in
cross-section taken along the cut-plane 27-27 of FIG. 26.
[0138] FIG. 42 is a perspective view of the outer housing of the
in-grade light of FIG. 24, wherein an installation cap is connected
to the open end of the outer housing.
[0139] FIG. 43 is an exploded view of the assembly of FIG. 42.
[0140] FIG. 44 is a perspective view of the assembly of FIG. 42
connected to a chairing structure and supports.
DETAILED DESCRIPTION
[0141] Outdoor light fixtures are often exposed to environmental
hazards such as moisture, temperature variants, dirt, wind,
sunlight, and other hazards. Additionally, like many electrical
devices, light fixtures often require routine and non-routine
maintenance for a variety of reasons. For example, light engines,
light bulbs, circuits, wiring, and other components of light
fixtures may have limited service lives and may require replacement
and/or repair. In some cases, one or more components of the light
fixture may be consumable, while all or most of the remaining
components are designed for long-term installation and use.
[0142] Repair and replacement of components in a light fixture,
especially an outdoor light fixture, can be costly, as the
maintenance services can require specially-trained technicians and
may require complete or substantially complete replacement of the
entire fixture. As such, it is desirable that the repair of light
fixtures be simplified to both reduce the cost of repair and to
expedite the process of repairing fixtures.
[0143] FIGS. 1 and 2 of the present disclosure illustrates an
embodiment of a light fixture 10 (e.g., an outdoor light fixture)
that can be configured to permit easy and simple repair and
replacement of many of the components of the fixture 10. It will be
understood that, though embodiments and components discussed herein
are discussed in the context of outdoor lighting, many or all of
the embodiments discussed herein can be also be used in an indoor
environment.
[0144] As illustrated, the light fixture 10 can include a housing
12. In some embodiments, the fixture 10 includes a light cover 14.
The light cover 14 can be configured to sealingly couple with the
housing 12. In some embodiments, the fixture 10 can include a mount
16 configured to facilitate installation of the fixture 12 at an
installation site (not shown) (e.g., an electrical box, a lighting
base, or some other installation site). In some embodiments (see,
e.g., FIG. 2A) the light fixture includes one or more cartridges 18
configured to be inserted and removed from the fixture housing.
Light Fixture Mount
[0145] As illustrated in FIGS. 1-3, in some embodiments, the mount
16 is rotatably or otherwise adjustably connected to the housing
12. For example, the mount can be connected to the housing 12 via a
mount connection 36 such as a hinge, a ball joint, a telescoping
connection, or some other adjustable connection or combination of
connections.
[0146] In the illustrated embodiment, the mount 16 is connected to
the housing 12 via a hinge 36 configured to rotate about a single
axis of rotation. Rotation of the housing 12 about the hinge 36 can
facilitate use of the fixture 10 in a variety of settings and
applications. For example, the fixture 10 can be used as an "up
light" when the housing 12 is rotated such that light is directed
upward. Rotation of the housing 12 downward can facilitate use of
the fixture 10 to illuminate the ground, low-lying landscaping, or
other features positioned closed to the ground.
[0147] In some embodiments, the mount connection 36 (e.g., hinge)
has a wide range of rotation. For example, the mount connection 36
may be configured to permit a range of rotation between the mount
16 and the housing 12 of at least about 20.degree., at least about
20.degree., at least about 45.degree., at least about 55.degree.,
at least about 70.degree., at least about 80.degree., at least
about 90.degree., and/or at least about 100.degree..
[0148] The mount connection 36 can include a feature configured to
permit locking and/or unlocking the mount connection 36. For
example, as illustrated, the hinge 36 can include a tightening
screw 38. The hinge 36 can be configured to lock (e.g., lock the
mount 16 in a given angular orientation with respect to the fixture
housing 12) when the screw 38 is tightened. In some embodiments,
loosening of the screw 38 can permit unlocking of the hinge 36,
permitting adjustment of the angular orientation of the fixture
housing 12 with respect to the mount 16. In some embodiments, the
hinge 36 may include a mechanical clamp that does not require a
screw.
[0149] In some embodiments, the mount 16 can include an attachment
structure 40 configured to connect with a corresponding attachment
structure (not shown) at an installation site. For example, as
illustrated, the mount 16 can include a threaded connector 40
(e.g., a male or female threaded connector) configured to connect
to a female or male threaded connector at the installation site. In
some embodiments, the attachment structure 40 includes one or more
of a detent connection structure, a friction-fit connection
structure, a snap fit, or other releasable connection
structure.
[0150] In some embodiments, as illustrated in FIG. 5, the mount 16
is at least partially hollow. One or more wires or other electrical
components (not shown) can extend through the mount 16. For
example, electrical wires for power and/or controlling the light
fixture 10 can extend through the mount 16. The wires can be
directed to a source of power and/or controls. In some embodiments,
potting material, gasket(s), and/or other sealing materials or
structures (not shown) are used to reduce or eliminate the
possibility of moisture ingress into the fixture 10 via the mount
16.
[0151] In some embodiments, the mount 16 is not hollow. In some
applications, power is provided to the fixture 10 via a battery
and/or wireless power. In some embodiments, control signals are
provided to the fixture 10 via wired and/or wireless signals.
Fixture Housing
[0152] Referring to FIG. 1, in some embodiments, the fixture
housing 12 has one or more surface features on the outer surface of
the fixture housing. For example, the fixture housing 12 can
include one or more heat dissipating structures 30 (e.g., heat
sinks) such as ribs, ridges, indentations, flanges, bumps,
protrusions and/or other structures configured to conductively
and/or convectively dissipate heat from the fixture housing 12. The
heat dissipating structure 30 can comprise indentations forming
ribs or otherwise thinned structures.
[0153] As illustrated in FIGS. 4 and 5, the fixture housing 12 can
define a fixture housing interior 20 and a fixture housing exterior
22. The fixture housing 12 can have a fixture housing axis 24
(e.g., a longitudinal axis and/or axial centerline). The fixture
housing axis 24 can extend through a first or closed end 26 (e.g.,
back end) and a second or open end 28 (e.g., front end) of the
fixture housing 12. The fixture housing axis can pass through the
light cover 14 when the light cover 14 is coupled with the fixture
housing 12.
[0154] The fixture housing interior 20 can include one or more
electrical connectors 32 configured to mate with complementary
electrical connectors 34 on the cartridge 18. For example, the
fixture housing 12 can include one or more female and/or male plugs
sized and shaped to releasably mate with complementary male and/or
female plugs on the cartridge 18.
Light Cover
[0155] In some embodiments, the light cover 14 can be removably
connected to the housing 12. In some configurations, the light
cover 14 is connected to the housing 12 via a hinge or other
permanent or semi-permanent connection structure. The light cover
14 can be configured to transition between an opened position
(e.g., providing access to an interior of the housing 12) and a
closed position (e.g., closing off access to an interior of the
housing 12). In some embodiments, the light cover 14 is configured
to connect to a front, back, or lateral side of the light housing
12.
[0156] Referring to FIG. 5, the light cover 14 can include a frame
42. In some embodiments, a lens 46 is connected to the frame. For
example, a lens 46 can be releasably or fixedly attached to the
frame 42. Preferably, the lens 46 is attached to the frame in a
fluid-tight or liquid-tight manner. For example, the lens 46 can be
attached to the frame 42 using adhesives (e.g., silicone adhesive
bonds). In some embodiments, the lens 46 is attached to a side of
the frame 42 closer to the fixture housing 12 (e.g., on an inner
side of the frame 42). In some embodiments, the lens 46 is attached
to a side of the frame 42 further from the fixture housing 12
(e.g., on an outer side of the frame 42). The lens 46 can be
configured to remain in place as the light cover 14 transitions
between the opened and closed positions. In some embodiments, the
lens 46 is configured to move with the light cover 14 (e.g., with
the frame 42) as the light cover 14 moves between the opened and
closed positions.
[0157] In some embodiments, the lens 46 is constructed from glass.
In some cases, the lens 46 is constructed from a polymer. The lens
46 can be transparent or translucent. The lens 46 can be planar or
can have one or more concave or convex portions. In some
embodiments, the light cover 14 includes one or more diffusers in
front of (e.g., outside of the fixture 10 with respect to the lens
46) and/or behind (e.g., inside the fixture 10 with respect to the
lens 46) the lens 46.
[0158] Comparing FIGS. 1 and 6, the light cover 14 may or may not
include a shroud portion 48. Many different shroud configurations
may be used for the light cover 14. In some cases, a shroud 48 is
formed (e.g., injection molded or otherwise formed) as an integral
part of the light cover 14. In some embodiments, the shroud 48 is
formed as a separate part connected to the frame 42 of the light
cover 14 during assembly. In some cases, the shroud 48 is removably
attached to the frame 42. In some such embodiments, the shroud
configuration for a given light cover 14 can be modified before,
during, and/or after installation of the light fixture 10 to suit
the requirements of the given installation.
[0159] In some embodiments, as illustrated in FIGS. 7 and 8, the
frame 42 of the light cover 14 can include a mating portion 44. The
mating portion 44 can extend away from the lens 46 in a direction
toward the first end 26 of the fixture housing 12 when the light
cover 14 is mated with the fixture housing 12. The mating portion
44 can extend into or around the fixture housing 12 when the light
cover 14 is coupled with the fixture housing 12. The mating portion
44 can be connected to the fixture housing 12 in a water-tight or
fluid-tight manner. For example, in some embodiments, the mating
portion 44 includes one or more seals 49. The seals 49 can be, for
example, O-rings, gaskets, and/or other sealing features. In some
embodiments, the seals 49 comprise one or more O-rings configured
to inhibit or prevent ingress of moisture, dirt, and/or other
environmental hazards into the fixture housing 12 when the light
cover 14 is coupled with the fixture housing 12. The O-rings 49 can
be positioned in one or more grooves or recesses on an inner or
outer surface of the mating portion 44 of the light cover 14. In
some embodiments, the O-rings 49 are positioned in grooves on the
interior or exterior of the fixture housing 12 between the mating
portion and the fixture housing 12. In some embodiments, multiple
successive seals 49 are used to provide redundant leak resistance
in the event of failure of one or more seals 49. For example, as
illustrated in FIG. 7, the fixture 10 can include two seals 49
between the mating portion 44 of the light cover 14 and the fixture
housing 12.
[0160] The light cover 14 can be configured for easy and fast
installation and/or removal from the fixture housing 12. For
example, as illustrated in FIGS. 6-8, the light cover 14 can
include one or more access holes 50 through which a fastener 52 may
be inserted. In some embodiments, the light cover 14 includes a
single access hole 50. In some such embodiments, the light cover 14
can be securely coupled with the fixture housing 12 via alignment
of the access hole 50 of the cover with a fastener hole 54 in the
fixture housing 12, coupling of the mating portion 44 of the light
cover 14 with the interior or exterior of the fixture housing 12,
and insertion and tightening of a fastener 52 through the access
hole 50 and into the fastener hole 54 of the fixture housing 12.
Removal of the light cover 14 from the fixture housing 12 may be
accomplished via loosening and/or removing the fastener 52 from the
access hole 50 and fixture hole 54 and decoupling of the mating
portion 44 of the light cover 14 from the fixture housing 12. In
some embodiments, the mating portion 44 or some other portion of
the light cover 14 may include a keyed feature configured to couple
with the fixture housing 12 in only a finite number of orientations
to facilitate easy alignment of the access hole 50 with the
fastener hole 54. In some embodiments, the light cover 14 is
coupled with the fixture housing 12 without use of fasteners. In
some such cases, clips, detents, or other releasable mating
structures can be used to couple the light cover 14 with the
fixture housing 12. In some embodiments, both the light cover 14
and fixture housing 12 include complementary threaded portions
configured to threadedly engage with each other.
[0161] In some embodiments, the light cover 14 is configured to
inhibit or prevent accumulation of water, dirt, or other substances
on the exterior of the lens 46 (e.g., the side of the lens 46
facing away from the interior 20 of the fixture housing 12 when the
light cover 14 is coupled with the fixture housing 12) and/or
elsewhere on the light cover 14. For example, the frame of the
light cover 14 can align the lens at a non-perpendicular offset
angle 56 with respect to the axis 24 of the fixture housing 12
(e.g., a longitudinal axis of the fixture housing 12). In some
embodiments, the offset angle 56 of the lens with respect to
perpendicular of the fixture housing axis 24 is between about
5.degree. and 10.degree., between about 3.degree. and 15.degree.,
between about 7.degree. and 12.degree., and/or between about
11.degree. and about 20.degree.. In some embodiments, the offset
angle 56 of the lens is greater than 20.degree..
[0162] The lens 46 can be oriented such that a first end 58 of the
lens 46 is positioned further rearward (e.g., closer to the fixture
housing 12) than a second, opposite end 60 of the lens 46 when the
light cover 14 is coupled to the fixture housing 12. As can be seen
in FIG. 7, the end of the lens 46 closest to the mount 16 (e.g.,
the first end 58 of the lens 46) is positioned further back than
the end of the lens 46 furthest from the mount 16 (e.g., the second
end 60 of the lens 46) when the light cover 14 is coupled with the
fixture housing 12. In some embodiments, the first end 58 of the
lens 46 is visible from a viewpoint perpendicular to the fixture
housing axis 24 at a same position along the fixture housing axis
24. For example, a first portion 62 of the frame 42 of the light
cover 14 at and/or near the first end 58 of the lens 46 can be
positioned entirely at the same position along the fixture housing
axis 24 with respect to the lens 46 and/or closer to the mount 16
with respect to the lens 46. In some such configurations, water or
other substances which contact the lens 46 can flow, roll, or
otherwise move off the lens 46 under the influence of gravity. In
some embodiments, as illustrated in FIG. 7, the orientation of the
lens 46 can permit gravity-induced run off of substances when the
fixture housing axis 24 is within .+-.about 10.degree. of
vertical.
Cartridge
[0163] Moving to FIGS. 9-11, the light fixture 10 can include a
cartridge 18. The cartridge 18 can be configured to removably
connect to the light housing 12. The cartridge 18 can include
numerous structural features and components configured to house,
maintain, or otherwise integrate with one or more
electrical/lighting features and components. The cartridge 18 can
be configured to facilitate removal, repair, installation, and/or
other customization of the lighting features connected to the
cartridge 18. For example, unlike standard "smart" light bulbs, the
cartridge 18 can be configured such that one or more light engines,
controllers, plugs, sensors, and/or other components may be
replaced and/or swapped with other components.
[0164] One or more of the structural features of the cartridge 18
can be configured to releasably mate with one or more features of
the fixture housing 12 and/or with one or more features of the
light cover 14. The structural features of the cartridge 18 can be
configured to facilitate quick and easy installation and removal of
the cartridge 18 to and from the housing 12. For example, the
cartridge 18 can be configured to be removable from the housing 12
via a twist and pull movement without use of threading or other
features common to other lighting structures. In some embodiments,
one or more of the electrical/lighting features of the cartridge 18
are configured to releasably mate with one or more features of the
fixture housing 12 and/or with one or more features of the light
cover 14. In some embodiments, the installation of the cartridge 18
o the fixture housing 12 connects an electrical grounding path.
Cartridge Structural and Mechanical Connection Features
[0165] Moving to FIGS. 12 and 13, the structural features of the
cartridge 18 can include a cartridge housing 72. In some
embodiments, the structural features can include a collar 74
connected to the cartridge housing 72. The collar 74 can be
configured to releasably connect with one or more features of the
fixture housing 12 when the cartridge 18 is coupled with the
fixture housing 12. For example, the collar 74 can include features
configured to releasably connect to one or more features of the
light housing 12 to inhibit or prevent accidental or inadvertent
disconnection between the cartridge 18 and the light housing 12. In
some embodiments, the collar 74 includes one or more alignment
features configured to facilitate alignment of the cartridge 18
with respect to the housing 12 before and/or during installation
and/or removal of the cartridge 18 with respect to the housing
12.
[0166] In some embodiments, the cartridge 18 includes one or more
structural features configured to facilitate manipulation of the
collar 74. For example, the cartridge 18 can include a handle 76
connected to the collar 74. The handle 76 can be configured to
facilitate rotation of the collar 74 about the cartridge housing
72. In some embodiments, the handle 76 is configured to facilitate
manual gripping of the cartridge 18 during installation and/or
during removal of the cartridge 18 from the housing 12.
[0167] The cartridge housing 72 can have a first end 78 (e.g., a
back end or an end directed toward the fixture housing 12 during
coupling/decoupling of the cartridge 18 with or from the fixture
housing 12) and a second end 80 (e.g., a front end or an end
directed away from the fixture housing 12 during
coupling/decoupling of the cartridge 18 with or from the fixture
housing 12). The cartridge 18 can include a cartridge axis 82
(e.g., a longitudinal and/or central axis). The cartridge axis 82
can pass through the first and second ends 78, 80 of the cartridge
18. In some embodiments, the cartridge axis 82 is parallel or
substantially parallel to the fixture housing axis 24 when the
cartridge 18 is coupled with the fixture housing 12. In some
embodiments, the cartridge axis 82 is parallel to or substantially
collinear with the fixture housing axis 24 when the cartridge 18 is
coupled with the fixture housing 12. In some embodiments, the
cartridge axis 82 and fixture housing axis 24 are not parallel to
each other when the cartridge 18 is coupled with the fixture
housing 12. In some embodiments, the cartridge housing 72 includes
one or more seals (e.g., O-rings, gaskets, or other seals)
configured to sealingly engage with one or more of the fixture
housing 12 and the light cover 14.
[0168] As illustrated in FIG. 12, the cartridge housing 72 can
include an alignment structure 84. The alignment structure 84 can
be configured to facilitate proper alignment between the cartridge
18 and the fixture housing 12 during coupling and/or decoupling of
the cartridge 18 with or from the fixture housing 12. Proper
alignment during coupling and/or decoupling of the cartridge 18
with or from the fixture housing 12 can reduce the risk of damage
to the cartridge 18 and/or to the fixture housing 12 due to
improper alignment.
[0169] The alignment structure 84 can comprise, for example, one or
more ridges (e.g., rails) configured to fit into one or more
channels 86 (FIG. 10) or indentations in fixture housing 12 when
the cartridge 18 is coupled with the fixture housing 12. In some
embodiments, the alignment structure 84 comprises a channel
configured to receive a protrusion or ridge of the fixture housing
12 when the cartridge 18 is coupled with the fixture housing 12.
The alignment structures 84 of the cartridge can be arranged (e.g.,
about the cartridge axis 82) in a pattern which inhibits or prevent
engagement of the cartridge alignment structures 84 with the
complementary alignment structures 86 of the fixture housing 12 in
more than one rotational orientation (e.g., about the cartridge
axis 82 and/or about the fixture housing axis 24). In some
embodiments, the alignment structures 84 of the cartridge 18 are
arranged in a pattern which permits engagement of the alignment
structures 84 of the cartridge 18 and fixture housing 12 in only a
single rotational orientation. For example, a pair of alignment
structures can be positioned on opposite sides of the cartridge.
The cartridge can also be shaped so as to only fully advance into
the fixture in the proper orientation (i.e. right side up). In some
embodiments, the alignment structures 84 of the cartridge 18 can
include one or more coupling features such as detents, snaps, or
other features configured to releasably connect to complementary
structures in or on the fixture housing 12.
[0170] In some embodiments, as illustrated in FIGS. 11 and 13, the
cartridge housing 72 can include one or more pads 88. The pads 88
can be constructed from a conductive and/or compressible material.
For example, the pads 88 can be constructed from a thermally
conductive elastomer. The pads 88 can be positioned such that they
are compressed as the cartridge 18 is moved into connection with
the fixture housing 12. In some embodiments, the pads 88 are
configured to conduct heat from the cartridge 18 to the fixture
housing 12 during and/or after use of the light fixture 10. For
example, the pads 88 can be thermally connected to the cartridge 18
and/or fixture housing 12 when the cartridge 18 is installed in the
housing 12. In some cases, thermal grease, conductive filler, or
other materials can be used instead of or in addition to the pads
88 to facilitate thermal conduction between the cartridge 18 and
the fixture housing 12.
[0171] In some embodiments, as illustrated in FIG. 10, the fixture
housing 12 includes one or more pads 89 configured to contact the
cartridge 18 (e.g., the cartridge housing 72) when the cartridge 18
is coupled with the fixture housing 12. The pads 89 can be
constructed from a conductive and/or compressible material (e.g., a
same or similar material as that from which the pads 88 of the
cartridge housing 72 are constructed). For example, the pads 89 can
be constructed from a conductive and compressible material and can
conduct heat away from the cartridge 18 during operation of the
lighting fixture 10. Compression of the pads 89 between the
cartridge 18 and the fixture housing 72 can facilitate dissipation
of heat from the cartridge 18 to the fixture housing 72 when the
cartridge 18 is coupled with the fixture housing 72. In some
embodiments, the one or more pads 89 of the fixture housing 72
contact and/or align with the one or more pads 88 of the cartridge
housing 72 when the cartridge 18 is mated with the fixture housing
12. In some embodiments, the fixture housing 72 does not include
pads, but includes surfaces sized and shaped substantially the same
as the pads 89. In some embodiments, the cartridge 18 does not
include pads, but includes surfaces 88a (FIG. 22) sized and shaped
to interact with the pads 89.
[0172] Moving to FIGS. 12 and 13, the collar 74 can be connected to
the cartridge housing 72 at or near the second end 80 of the
cartridge housing 72. The collar 74 can be configured to rotate
about the cartridge axis 82 with respect to the cartridge housing
72. In some embodiments, the collar 74 is fixed in a direction
parallel to the cartridge axis 82 with respect to the cartridge
housing 72. The collar 74 can be configured to releasably connect
to one or more portions of the fixture housing 12 to facilitate
coupling of the cartridge 18 with the fixture housing 12.
[0173] In some embodiments, the collar 74 is configured to rotate
freely about the cartridge housing 72 in either direction of
rotation about the cartridge housing axis 82. In some embodiments,
the collar 74 is inhibited from rotating about the cartridge
housing 72 outside of a predetermined range. For example, the
collar 74 and/or cartridge housing 72 can include one or more
structures (e.g., protrusions, tabs, and/or other structures)
configured to limit the rotational range of the collar 74 with
respect to the cartridge housing 72. In some embodiments, the
rotational limits defining the predetermined range of rotation of
the collar 74 comprise a first rotational position (e.g., an
unlocked position) and a second rotational position (e.g., a locked
position).
[0174] Referring to FIGS. 12 and 13, the collar 74 can include one
or more coupling structures 90 configured to mate with
complementary structure(s) on or in the fixture housing 12. For
example, the collar 74 can include one or more tabs 90 or
protrusions extending from an outer surface of the collar 74.
[0175] The one or more protrusions 90 can be configured to engage
and disengage with a coupling structure of the fixture housing 12
during coupling and decoupling of the cartridge 18 from the fixture
housing 12. For example, as illustrated in FIGS. 14A and 14B, the
fixture housing 12 can include a tab slot 92 configured to receive
the tab 90 of the collar 74 when the collar 74 is in the unlocked
position. The tab 90 and tab slot 92 can engage in a bayonet-type
coupling wherein the tab 90 enters a tab opening 94 in the tab slot
92 as the cartridge 18 is moved into the fixture housing 12. The
tab 90 can then be moved along the tab slot 92 as the collar 74 is
rotated with respect to the fixture housing 12 (e.g., and rotated
with respect to the cartridge housing 72, as illustrated, for
example, in FIGS. 9 and 10) to the locked position. Interference
between the tab and the wall of the tab slot can inhibit or prevent
movement of the collar 74 in a direction parallel to the fixture
housing axis 24 with respect to the fixture housing 12 when the tab
90 is rotated into the tab slot 92. In some embodiments, the tab
slot 92 includes one or more stops configured to limit the range of
movement of the tab 90 within the tab slot 92.
[0176] In some embodiments, as illustrated in FIGS. 15A-15C, the
tab slot 92' include a sloped (e.g., helical) surface 96. The
sloped surface 96 of the tab slot 92' can be configured to move the
tab 90 (e.g., and thus the cartridge 18) toward the first end 26 of
the fixture housing 12 as the tab 90 is rotated in the tab slot 92'
during coupling of the cartridge 18 with the fixture housing 12.
Rotation of the tab 90 in an opposite direction can move the
cartridge 18 away from the first end 26 of the fixture housing 12.
Movement of the cartridge 18 toward the first end 26 of the fixture
housing 12 during rotation of the collar 74 can facilitate a
reliable and/or sure electrical and/or thermal connection between
the cartridge 18 and the fixture housing 12.
[0177] In some embodiments, the cartridge 18 includes one or more
features configured to facilitate easier rotation of the collar 74
and/or movement of the cartridge 18 toward and away from the
fixture housing 12. For example, as illustrated in FIGS. 16 and 17,
the cartridge 18 can include a handle 76 or other tactile
portion.
[0178] The handle 76 can be connected to the cartridge housing 72
and/or to the collar 74. The handle 76 can be configured to
transition between one or more configurations. For example, the
handle 76 can be configured to rotate about one or more axes of
rotation with respect to the cartridge housing 72 and/or collar 74.
In some embodiments, the handle 76 rotates in unison with the
collar 74 with respect to the cartridge housing 72 about a first
axis of rotation (e.g., an axis rotation parallel to or
substantially parallel to the cartridge axis 82). In some
embodiments, the handle 76 is configured to rotate with respect to
both the cartridge housing 72 and the collar 74 about a second axis
of rotation 98. The second axis of rotation 98 can be perpendicular
to or otherwise non-parallel with the first axis of rotation.
[0179] Rotation of the handle 76 about the second axis 98 can
transition the handle 76 between a first and a second
configuration. The first configuration can be, for example, a
stored (e.g., closed) configuration, as illustrated in FIGS. 8 and
12. The second configuration can be an actuation position, as
illustrate in FIGS. 9-11, 16 and 17. In some embodiments,
transition of the handle 76 to the stored configuration can move
the handle 76 (e.g., and the subcomponents thereof) out from a path
of light emitted from the cartridge 18. Transition of the handle 76
to the actuation position can facilitate easier rotation of the
handle 76 and/or pulling/pushing of the handle 76.
[0180] As illustrated in FIGS. 16 and 17, the handle 76 can include
a gripping portion 100. In some embodiments, the handle 76 includes
a hinge or other rotation structure configured to facilitate
rotation of the gripping portion 100 with respect to the cartridge
housing 72 and/or with respect to the collar 74.
[0181] The gripping portion 100 can have an arcuate shape extending
between a first gripping end 102 and a second gripping end 104. The
arcuate shape of the gripping portion 100 can curve about the
cartridge axis 82 and/or the first axis of rotation when the handle
76 is in the stored configuration. In some embodiments, a radius of
curvature of the gripping 100 portion is similar to or the same as
a radius of curvature of the collar 74. The radius of curvature of
the gripping portion 100 can be greater than a radius of the light
unit assembly 110 (described below) and/or of some components
thereof. In some embodiments, the arcuate shape of the gripping
portion 100 facilitates movement of the gripping portion 100 out of
the light emission path of the cartridge 18 when the handle 76 is
in the stored configuration. In some embodiments, the gripping
portion 100 is formed as a monolithic part. In some case, the
gripping portion 100 is constructed from a plurality of separate
components.
[0182] The rotation structure can comprise one or more structures
configured to facilitate movement of the gripping portion 100 about
the second axis of rotation 98. For example, as illustrated in
FIGS. 16 and 17, the rotation structure can include a first track
106 connected to the first gripping end 102. In some embodiments,
the rotation structure includes a second track 108 connected to the
second gripping end 104.
[0183] The first and/or second tracks 106, 108 can have an arcuate
shape and a track portion extending along a length of the
respective tracks 106, 108. In some embodiments, the arcuate shape
of the tracks 106, 108 curve around the second axis of rotation 98.
In some embodiments, the tracks 106, 108 have curved profiles along
a length of the first and/or second tracks 106, 108. The curved
profile of the tracks can be configured to fit around an outer
dimension (e.g., outer radius) of the electrical/lighting features
of the cartridge as the handle 76 is transitioned between the
stored and actuation positions. A radius of curvature of the curved
profile of the first and/or second tracks 106, 108 can be similar
to, the same as, or smaller than the radius of curvature of the
collar 74.
[0184] The first and/or second tracks 106, 108 can be configured to
ride along a corresponding structure of the collar 74. For example,
the collar 74 can include one or more protrusions configured to sit
in the first and/or second tracks 106, 108. In some embodiments,
the protrusions can engage an end surface 107 (FIG. 13) in the
track to cause the tracks 106, 108 to inhibit or prevent rotation
when the handle 76 is in its actuation position. In some
embodiments, the collar 74 includes one or more apertures 77 that
confine at least one side of the first and/or second tracks 106 or
108. A surface may be formed on the inner side of the collar 74
that forms a slot with the aperture 77 through which the tracks
106, 108 are configured to slide. The track apertures can include
tabs or other features configured to confine at least three sides
of the tracks 106 and 108. Interference between the tabs and the
ends of the channels of the tracks 106, 108 can define one or more
rotational limits of the handle 76 between the stored and actuation
positions. In some embodiments, interference between the gripping
portion 100 and the collar 74 defines a rotational limit for the
stored configuration.
[0185] In some embodiments, the cartridge 18 is configured to be
inserted into and/or removed from the light housing 12 through a
portion of the light housing 12 other than the second end 28 of the
housing 12. For example, the cartridge 18 may be configured to be
inserted through the first end 26 and/or through a sidewall between
the first and second ends 26, 28 of the housing 12. The structural
elements of the cartridge 18 described above (e.g., the collar 74
and/or handle 76 can be at various locations (e.g., the first end
78, second end 80, or in between) on the cartridge 18 to facilitate
coupling of the cartridge 18 with the housing 12 at locations other
than the second end 28 of the housing 12.
Cartridge Electrical and Lighting Features
[0186] As mentioned above, the cartridge 18 can include one or more
electrical and/or lighting components. These components can be
connected to, integral with, and/or otherwise associated with the
structural components of the cartridge 18 described above.
[0187] Moving to FIG. 18, the electrical/lighting components can
include a light unit assembly 110. The light unit assembly 110 can
be configured to generate light and direct that light with desired
lighting characteristics (e.g., shape, intensity, direction, color,
and/or other characteristics) from the cartridge 18. In some
embodiments, the handle 76 (e.g., the gripping portion 100 and/or
tracks 106, 108) are shaped and sized to move around the light unit
assembly 110 when transitioning between the stored and actuation
positions.
[0188] The light unit assembly 110 can be powered by a battery or
other source of power in the cartridge 18. In some embodiments, the
cartridge 18 includes one or more electrical connections 112 (e.g.,
plugs) (see FIGS. 11 and 13) configured to electronically connect
with complementary electronic features of the light fixture 10.
Preferably, the cartridge 18 includes one or more drivers 114 (see
FIGS. 22 and 23). The one or more drivers 114 can be configured to
process and/or generate signals to control functions of the light
unit assembly 110 (e.g., ON/OFF, timing, and/or one or more of the
lighting characteristics described above).
[0189] The light unit assembly 110 can include a light engine 116
configured to generate light. In some embodiments, the light unit
assembly 110 includes a beam reflector 118 and/or a beam director
120 (FIGS. 19B-21), each of which can be configured to alter the
shape and/or intensity of the light generated by the light engine
116.
[0190] Referring to FIG. 18, the light engine 116 can be or include
a light emitting diode 122 (LED) or an array of multiple LED's. In
some embodiments, the light engine 116 is a light bulb (e.g., an
incandescent, fluorescent, halogen, or other bulb type). In some
embodiments, the light engine 116 includes one or more circuit
boards and/or other electrical components. The light engine 116 can
be electronically connected to one or more sources of power and/or
to one or more control units. For example, as illustrated, the
light engine 116 can include a plug 124 or other electrical
connector configured to mate with the driver 114 and/or with some
other component of the cartridge 18.
[0191] The light engine 116 can be attached to some portion of the
cartridge housing 72 via, for example, fasteners, adhesives,
soldering, and/or welding. In some embodiments, as illustrated in
FIG. 7, the light engine 116 is connected to a wall 126 of the
cartridge housing 72 between the first and second ends 78, 80 of
the cartridge housing 72. In some embodiments, the wall 126 is
configured to at least partially thermally separate the light
engine 116 from other components of the cartridge 18 (e.g., from
the driver(s) 114). The light engine 116 can be directed toward
(e.g., face) the second end 80 of the cartridge housing 72.
[0192] In some embodiments, the light unit assembly 110 includes a
beam reflector 118. Beam reflectors 118 of various shapes and sizes
may be used in the light unit assembly 110 (e.g., compare the beam
reflector 118 in FIG. 18 with the beam reflector 118' in FIG. 7) to
accommodate specific lighting requirements. The beam reflector 118
can be configured to direct light from the light engine 116 in a
predetermined pattern.
[0193] The beam reflector 118 can be connected to the light engine
116 directly or indirectly. For example, the beam reflector 118 can
be connected to the light engine 116 via one or more fasteners
and/or some other connection structure or method. In some
embodiments, as illustrated in FIG. 18, the light unit assembly 110
can include a connecting frame 128 configured to facilitate
releasable or fixed connection between the beam deflector 118 and
the light engine 116. In some embodiments, the connecting frame 128
is connected to the light engine 116 via adhesive, fasteners (e.g.,
fasteners 129), and/or other connection structures or methods.
[0194] The connecting frame 128 can be configured to couple and
decouple with the beam reflector 118 via a bayonet connection,
threaded connection, detent connections, or some other releasable
connection. Using a releasable connection between the beam
reflector 118 and the connecting frame 128 or between the beam
reflector 118 and the light engine 116 can facilitate easy and
quick changing of the beam reflector 118 of one configuration for a
beam reflector 118' of another configuration.
[0195] In some embodiments, the beam reflector 118 includes one or
more arms 131 or other structures configured to connect to the
connecting frame 128 and/or to the light engine 116. For example,
the arms 131 can be configured to couple and decouple from the
connecting frame 128 via a bayonet connection and/or via use of the
fasteners 129. In some embodiments, the one or more arms 131 are
configured to receive one or more fasteners 129 to connect to the
connecting frame 128 and/or to the light engine 116 with or without
a bayonet connection.
[0196] Turning to FIGS. 16-18, the light unit assembly 110 can
include one or more optical components 130. The optical
component(s) 130 can be, for example, one or more of a diffuser, a
color filter, secondary lens, and/or some other optical component.
As illustrated in FIG. 7, the optical component 130 can be
positioned between the light engine 116 and the lens 46 of the
light cover 14 when the light fixture 10 is assembled.
[0197] In some embodiments, one or more optical components 130 are
connected to the beam reflector 118 (e.g., via adhesives, clips, or
other attachment structures). In some embodiments, the one or more
optical components 130 are held in place via retention structures
on the cartridge 18, the light cover 14, or some other component of
the fixture 10. For example, the collar 74 can include one or more
clamps 132 (see, e.g., FIGS. 17 and 18) configured to retain the
optical component(s) in place with respect to the cartridge 18. In
some embodiments, the clamps 132 retain the optical component(s)
130 in place in a releasable manner, thereby permitting exchange of
one or more optical components 130 for other optical
components.
[0198] In some embodiments, as illustrated in FIGS. 19A-21, the
light unit assembly 110 can include beam director 120. The beam
director 120 can be used instead of, or in addition to, a beam
reflector 118. In some embodiments, the beam director 120 is
positioned between the light engine 116 and the lens 46 of the
light cover 14 when the light fixture 10 is assembled. For example,
the beam director 120 can be connected directly to the light engine
116 in a fixed or releasable manner. In some embodiments, the beam
director 120 is connected to the light engine 116 via one or more
fasteners, clips, detents, or other structures configured to
facilitate releasable connection between the light engine 116 and
the beam director 120. In some such embodiments, a beam director
120 installed in the light unit assembly 110 can be exchanged for
another beam director 120' without use of complex tools (e.g.,
other than simple screwdrivers or other hand tools).
[0199] The beam director 120 can include one or more protrusions
136 configured to at least partially shroud and reflect the light
emitted from the light engine 116. The protrusions 136 of the beam
director 120 can be arranged in patterns to produce predetermined
light emissions patterns for the light engine 116. For example, the
beam director 120 illustrated in FIG. 20 can include two opposing
protrusions 136 to form a rectangular light pattern. A second beam
director 120' is illustrated in FIG. 21 including a light wall 136'
extending from the beam director 120' away from the extender 138
and/or from the light engine 116. In some embodiments, the light
wall 136' is continuous around a perimeter of the beam director
120. The light wall 136' can have a plurality of sides. For
example, the light wall 136' can have four sides and can be
configured to produce a square light pattern. Many other
light-directing shapes, including ellipses, polygons, and
combinations thereof, can be produced by beam directors with
appropriate protrusion arrangements.
[0200] As best shown in FIGS. 19B and 21, the light unit assembly
110 can include a light unit extender 138. The light unit extender
138 can be positioned between the light engine 116 and the first
end 78 of the cartridge 18. In some embodiments, the light extender
138 is positioned between the light engine 116 and the wall 126 of
the cartridge 18. The light extender 138 can be configured to
position the light engine 116 nearer the second end 80 of the
cartridge 18. Positioning the light engine 116 at or near the
second end 80 of the cartridge 18 can facilitate higher degrees of
angulation between the light engine 116 and the cartridge axis 82
than may be feasible if the light engine 116 is positioned closer
to the first end 78 of the cartridge 18. For example, positioning
the light engine 116 closer to the second end 80 of the cartridge
18 reduces the likelihood that the collar 74 or other cartridge
structure would interfere with the light transmission path of the
light engine 116.
[0201] The light extender 138 can include an extender base 140 at a
first end of the light extender 136. The second end of the light
extender 136 can include a light engine base 142. The light
extender 136 can include an elongate and/or columnar extension
portion 144 connecting the extender base 140 to the light engine
base 142. In some embodiments, the light extender is constructed
from a metal or other conductive material configured to dissipate
heat from the light engine 116. In some embodiments, the light
extender 138 is constructed from a polymer material.
[0202] The extender base 140 can be connected to the wall 126 or
other structure of the cartridge 18. In some embodiments, the
extender base 140 is connected to the cartridge housing 18 via one
or more fasteners, adhesives, welding, and/or other fixed or
releasable connection methods or structures. In some embodiments,
extender base 140 includes one or more fastener holes. One or more
of the fastener holes of the extender base 140 can be arranged in a
same pattern as one or more of the fasteners holes on the light
engine 116. In some such embodiments, a technician or other user of
the cartridge 18 can remove the light extender 138 from and/or add
a light extender 138 to a cartridge 18 without making any
structural changes to other components in the cartridge 18.
[0203] The light engine base 142 can be configured to connect to
the light engine 116. For example, the light engine base 142 can be
configured to connect to the light engine via one or more
fasteners, adhesives, welding, and/or other fixed or releasable
connection methods or structures. In some embodiments, the light
engine base 142 includes one or more fastener holes. One or more of
the fastener holes of the light engine base 142 can be arranged in
a same pattern as one or more fastener holes in the cartridge
housing 18 (e.g., in the wall 126). In some such embodiments, the
same light engine 116 may be attached to the light engine base 142
or to the cartridge housing 72, in accordance with the existence or
absence of a light extender 138.
[0204] The extension portion 144 of the light extender 138 can
include one or more ribs, protrusion, channels, or other
heat-dissipating structural elements. The heat-dissipating
structural elements of the extension portion 144 can be configured
to dissipate heat from the light engine 116 before, during, and/or
after use of the light fixture 10.
[0205] As illustrated in FIG. 19B, the light engine base 142 can be
tilted or otherwise non-parallel to the extender base 140. Angular
offset between the light engine base 142 and the extender base 140
can permit direction of the light from the cartridge 18 in a
direction tilted from the fixture housing axis 24. In some
embodiments, the extender 136 can be used in combination with beam
directors 120 and/or beam reflectors 118 to generate customized
light patterns from the light fixture 10. In some embodiments, the
light engine base 142 and extender base 140 are positioned parallel
to each other (not shown).
[0206] Turning to FIGS. 22 and 23, the driver 114 can be configured
to couple with the cartridge housing 72. In some embodiments, the
cartridge housing 72 includes a driver recess 146. The driver
recess 146 can be sized and/or shaped to receive drivers 114 of
varying sizes.
[0207] The cartridge 18 can include one or more driver securement
features configured to retain the driver 114 in connection with the
cartridge 18. The securement features can be configured to
accommodate drivers 114 of various sizes and/or shape. In some
embodiments, the securement features are configured to tighten or
otherwise increase the stability of the connection between the
driver 114 and the cartridge housing 72.
[0208] The driver 114 securement features can include, for example,
a clamp 150. The clamp 150 can be adjustable. For example, the
clamp 150 can have a first end 152 adjustably connected to the
cartridge housing 72 and a second end 154. The second end 154 of
the clamp 150 can extend over a portion of the driver recess 146.
The clamp 150 can include an adjustment feature configured to move
the second end 154 of the clamp 150 toward and away from the driver
recess 146. For example, the clamp 150 can include a screw 156 or
other adjustable feature. In some embodiments, tightening the screw
156 at the first end 152 of the clamp 150 can move the second end
154 of the clamp 150 toward the driver recess 146 (e.g., toward the
driver 114). Further tightening of the screw 156 can tighten the
second end 154 of the clamp 150 against the driver 114. In some
embodiments, loosening of the screw 156 can permit movement of the
second end 154 of the clamp 150 away from the driver 114 and/or
away from the driver recess 146. Additional securement features
such as, for example, detents, clips, high-friction surfaces,
and/or other securement features can be used in addition to or
instead of the clamp 150.
[0209] As illustrated in FIG. 22, the driver 114 can include a
first electrical connector (e.g., a plug) 160. The first electrical
connector 160 can be configured to couple with the electrical
connector 124 of the light engine 116 (FIG. 18). In some
embodiments, the driver 114 includes a second electrical connector.
For example, the driver 114 can include the plug 112 configured to
electrically connect with the plug 113 of the fixture housing 72
(see, e.g., FIG. 10). In some embodiments, the driver 114 includes
a power source (e.g., a battery). In some such embodiments, the
driver 114 does not include a second plug.
[0210] The driver 114 can be configured to receive and/or process
signals from a remote signal source. The remote signal source can
be a server or other signal generator. In some embodiments, the
driver 114 receives the signals via the second plug 112. In some
embodiments, the driver 114 receives signals via a wireless
connection. The driver 114 can be configured to process the signals
to facilitate operation of the light unit assembly 110 (e.g.,
ON/OFF, dimming/brightening, color changing, and/or other
operations of the light unit assembly 110). In some embodiments,
the driver 114 is embedded with one or more signal algorithms
configured to operate the light unit assembly 110 without
additional signal reception from a signal generator. In some
applications, the driver 114 is configured to receive line voltage
(e.g., high voltage) and output a constant current to drive the
light engine 116. In some embodiments, the driver 114 is configured
to receive line voltage and output a lower voltage to the light
engine 116. For example, the light engine 116 may include
additional circuitry configured to use the voltage output from the
driver 114 to drive the LEDs or other light units. In some
embodiments, the driver 113 is thermally connected to the cartridge
housing 72. In some embodiments, the light engine 116 receives line
voltage directly without use of a driver 114. In some cases, the
light engine 116 contains over-temperature circuitry and/or sensor
for motion or other features. In some embodiments, the light engine
116 is configured to process signals to facilitate operation of the
light unit assembly 110 (e.g., ON/OFF, dimming/brightening, color
changing, and/or other operations of the light unit assembly
110).H
Repair and/or Replacement of Electrical Components
[0211] As described above, the cartridge 18 can be constructed and
assembled to include many and/or most of the electrical components
of the light fixture 10. In some embodiments, the cartridge 18
includes all or most of the consumable components of the light
fixture 10. Positioning electrical and/or consumable components on
and in the cartridge 18 can facilitate easy and/or quick repair of
and/or other desired changes to the light fixture 10 in the
field.
[0212] For example, a method of repairing or replacing one or more
of the light engine 116, beam director 120, beam reflector 118,
driver 114, cartridge electrical connectors 112, and/or other
components of the cartridge 18 can include removing the fastener 52
from the light cover 14 and from the fixture housing 12 (FIG. 2A).
The light cover 14 can then be removed from the fixture housing 12.
In some cases, the light cover 14 may be reinstalled on the fixture
housing 12 while waiting to replace the cartridge 18 to reduce
exposure of the interior 20 of the fixture housing 12 to moisture
or other environmental hazards.
[0213] The cartridge 18 can be configured to pass into and out of
the housing interior 20 of the fixture housing 12. In some
embodiments, the cartridge 18 is configured to be removed from and
mated with the fixture housing 12 along a mating path 70 (FIGS. 10
and 11) parallel to or substantially parallel to the fixture
housing axis 24. In some embodiments, the mating path 70 of the
cartridge 18 is not parallel to the fixture housing axis 24.
[0214] A method of removing the cartridge from the fixture housing
12 can include rotating the handle 76 to the actuation
configuration. The technician or other user can rotate the collar
74 from the locked (FIG. 16) to the unlocked position (FIG. 17).
For example, the user can rotate the gripping portion 100 of the
handle 76 to rotate the collar 74. When the collar 74 is in the
unlocked position (e.g., when the tabs 90 are aligned with the tab
openings 94 of the fixture housing 12), the user can pull the
cartridge 18 out from the fixture housing 12.
[0215] In some cases, a replacement cartridge may be placed into
the fixture housing 12 prior to reinstallation of the light cover
14. The damaged cartridge can be repaired on-site or shipped to a
remote repair center. In some embodiments, the damaged cartridge
can be repaired in a nearby indoor facility to avoid exposure of
the cartridge components to environmental hazards.
[0216] To replace the same cartridge or connect another cartridge
to the fixture housing 12, the user can position the collar 74 of
the replacement cartridge in the unlocked position (FIG. 17). The
user can align the alignment structure 84 of the replacement
cartridge 18 with the corresponding alignment structure 86 of the
fixture housing 12. The user can push the cartridge 18 into
engagement with the fixture housing 12. In some embodiments,
pushing the replacement cartridge 18 into the fixture housing 12
electrically connects the electrical connector 112 of the cartridge
18 with the electrical connector 113 of the fixture housing 12.
After the tab 90 of the collar passes through the tab opening 94 of
the fixture housing 72, the collar 74 can be rotated to the locked
position.
In-Grade Light
[0217] In some applications, it may be desirable to install a light
on or at least partially in the ground. In-ground lights are
sometimes referred-to as "in-grade lights" (see e.g., FIG. 24).
In-Grade lights can provide desired lighting for applications such
as landscaping, structural lighting, pathway lighting, or other
applications where upward-directed light is desired. In-Grade
lights can also be used in applications to provide
downward-directed or sideways-directed light. In-Grade lights can
be installed in many environments including, but not limited to,
landscaping beds, concrete (e.g., walkways), and/or turf. In-Grade
lights can have a low profile (e.g., extend very little or not at
all in an upward direction from the ground). In-Grade lights can be
flush with or (entirely or partially) recessed from an adjacent
surface. In some applications, activities such as lawn mowing,
walking, pressure-washing, and/or other activities can be performed
on and/or near in-grade lights without negatively impacting the
integrity or performance of the light.
[0218] Because in-grade lights are often installed at least
partially underground, they are especially susceptible to moisture,
dirt, and other environmental hazards. Ingress of moisture into An
in-grade light can negatively affect the performance of the light.
For example, the lens of the light may accumulate moisture and
become cloudy or otherwise optically compromised. Moisture can
damage or destroy electrical components in the in-grade light. In
some cases, the position of the in-grade light can make replacement
and/or repair of parts within the light difficult due to the high
risk of moisture ingress into the light and the difficulty of
removing moisture from the light. Additionally, it can be difficult
to adjust the direction (e.g., angle, tilt, etc.) of the light
produced from the in-grade light, as it may be necessary to open
the light and permit ingress of moisture and other environmental
hazards into the light when adjusting the lighting direction.
[0219] As such, it would be advantageous to provide An in-grade
light configured to resist or eliminate moisture ingress into the
light before, during, and/or after replacement, repair and/or
adjustment of the light. Certain features and characteristics of
the in-grade lights described herein can facilitate replacement,
repair, and/or adjustment of in-grade light components with little
or no water ingress into the light and/or into portions of the
light housing electrical components.
[0220] An example of such An in-grade light 200 is illustrated in
FIGS. 24 and 25. The in-grade light 200 can include one or more
housings in which electrical and mechanical components are housed.
For example, the in-grade light 200 can include an outer housing
202. An inner housing assembly 204 may be positioned at least
partially within the outer housing 202 when the in-grade light 200
is assembled. The in-grade light 200 can include a cover 206
configured to couple with one or both of the outer housing 202 and
the inner housing assembly 204.
[0221] The in-grade light 200 can include a cartridge 18. The
cartridge 18 can be the same as or similar to the cartridges
described above. In some embodiments, the cartridge 18 can be
configured to releasably connect to one or both of the outer
housing 202 and the inner housing assembly 204.
[0222] As will be discussed in more detail below, the in-grade
light 200 can include one or more mechanisms or structures
configured to facilitate tilting and/or rotating of the cartridge
18 or some other component or system of components with respect to
the outer housing 202.
In-Grade Light Outer Housing
[0223] With reference back to FIG. 24, the outer housing 202 of the
in-grade light 200 can include a sleeve portion 208. The sleeve
portion 208 can have a first end (e.g., lower end) 214 and a second
end (e.g., upper end) 216. As best seen in FIG. 25, the second end
216 can be open. In some embodiments, the first end 214 is closed.
The outer housing 202 (e.g., the sleeve portion 208) is hollow or
at least partially hollow. The outer housing 202 can have an outer
housing axis 218 extending through one or both of the first and
second ends 214, 216 of the sleeve portion 208.
[0224] Returning to FIG. 24, the sleeve portion 208 can be
connected to a connection portion 210. The connection portion 210
can be, for example, positioned at the second end 216 of the sleeve
portion 208. The connection portion 210 can be configured to
connect to the inner housing assembly 204 and/or to the cover 206.
The outer housing 202 can include one or more electrical ports 212.
The one or more electrical ports 212 can be configured to
facilitate electrical connection between the interior of the outer
housing 202 and the exterior of the outer housing 212. The one or
more electrical ports 212 can be positioned at or near the first
end 214 of the sleeve portion 208.
[0225] The sleeve portion 208 can have a cylindrical or generally
cylindrical shape. In some embodiments, one or more segments of the
sleeve portion 208 have a different shape from one or more other
segments of the sleeve portion 208. For example, one or more
segments of the sleeve portion 208 can have a rectangular
cross-sectional shape (e.g., as measured perpendicular to the outer
housing axis 218), a triangular cross-sectional shape, an oval
cross-section, and/or some other polygonal or curved
cross-sectional shape.
[0226] With continued reference to FIG. 24, the sleeve portion 208
can have a plurality of segments between the first and second ends
214, 216 of the sleeve portion 208. A first segment 208a of the
sleeve portion 208 can be positioned closes to the first end 214 of
the sleeve portion 208. A second segment 208b of the sleeve portion
208 can be connected to the first segment 208a between the first
segment 208a and the second end 216 of the sleeve portion 208. In
some embodiments, the sleeve portion 208 includes a third segment
208c connected to the second segment 208b and positioned between
the second segment 208b and the second end 216 of the sleeve
portion 208. In some cases, the connection portion 210 of the outer
housing 202 is connected to the third segment 208c of the sleeve
portion 208. In some embodiments, each of the segments 208a, 208b,
208c of the sleeve portion 208 has a same or similar
cross-sectional shape and/or area. In some embodiments, the
cross-section of the third segment 208c is larger than the
cross-sections of one or both of the first and second segments
208a, 208b. In some embodiments, the cross-section of the second
segment 208b is larger than the cross-sections of one or both of
the first and third segments 208a, 208c. In some embodiments, the
cross-section of the first segment 208a is larger than the
cross-sections of one or both of the second and third segments
208b, 208c. As illustrated, the cross-section of the second segment
208b can be greater than the cross-section of the first segment
208a but smaller than the cross-section of the third segment
208c.
[0227] As illustrated in FIGS. 26 and 27, the outer housing 202 can
include a plurality of electrical ports 212. For example, the outer
housing 202 can include two electrical ports 212. Three or more
electrical ports 212 are also contemplated. The use of a plurality
of ports 212 can facilitate easier hardwiring between two or more
in-grade lights 200. The electrical ports 212 can positioned at or
near the first end 214 of the sleeve portion 208. In some
embodiments, the electrical ports 212 are positioned on opposite
sides (e.g., as measured perpendicular to the outer housing axis
218) of the sleeve portion 208 from each other. One or more of the
electrical ports 212 can be a stamped portion of the sleeve portion
208. The stamped portion can be punched out if or when the user
(e.g., installation technician) decides to use the electrical port
212 in question. Unused electrical ports 212 can be left un-punched
and impervious to fluid ingress or egress.
[0228] The electrical ports 212 can include threaded portions
configured to engage with electrical fittings. In some embodiments,
the electrical ports 212 are configured to engage with external
electrical fittings in a fluid and/or liquid-tight manner.
[0229] In some embodiments, as illustrated in FIGS. 27 and 28, the
in-grade light 200 includes an internal cap assembly 220. The
internal cap assembly 220 can be configured to fluidly isolate one
or more portions of the interior of the outer housing 202 from
other portions of the interior of the outer housing 202. More
specifically, in the illustrated embodiments, the internal cap
assembly 220 can be used to at least partially isolate the first
segment 208a of the sleeve portion 208 from the second segment 208b
of the sleeve portion 208. In some embodiments, the sleeve portion
(e.g., the second segment 208b) includes one or more drain holes
221 (FIG. 41). The drain holes 221 can be configured to permit
moisture to pass from the interior of the outer housing 202 to the
surrounding environment (e.g., to soil, concrete, and/or other
surrounding media). Draining the interior of the outer housing 202
can reduce the risk of water accumulation within the outer housing
202. The cap 220 can be configured to inhibit or prevent ingress of
moisture from the interior of the second or third segments 208b,
208c of the sleeve portion 208 into the first segment 208a.
Inhibiting or preventing moisture from entering the first segment
208a of the sleeve portion 208 can reduce the risk of moisture
contact with electrical connections within the first segment 208a
to reduce the risk of electrical shorts and other adverse
occurrences.
[0230] The internal cap assembly 220 can include a cap body 222.
The cap body 222 can be sized to fit snugly with an inner surface
of the sleeve portion 208 of the outer housing 202. For example,
the cap body 222 can be sized to fit snugly with an inner surface
of the first segment 208a of the sleeve portion 208. The internal
cap assembly 220 can include a seal (e.g., an O-ring) 224
configured to fit between an outer surface of the cap body 222 and
the inner surface of the first segment 208a. In some embodiments,
the cap body 222 includes one or more grooves configured to receive
the O-ring 224. The O-ring 224 can be configured to inhibit or
prevent passage of fluid between the cap body 222 and the inner
wall of the sleeve portion 208 (e.g., of the first segment 208a)
when the internal cap assembly 220 is coupled with the sleeve
portion 208. In some embodiments, the cap assembly 220 includes a
handle 232 or other gripping structure configured to facilitate
removal of the cap assembly 220 from the sleeve portion 208.
[0231] In some embodiments, the cap body 222 includes a sealing
wall 226 (FIG. 27) separating one portion of the interior of the
sleeve portion 208 from other portions of the interior of the
sleeve portion 208. For example, the sealing wall 226 can fluidly
separate the one or more electrical ports 212 from the inner
housing assembly 204 of the in-grade light 200 when the in-grade
light 200 is assembled. The sealing wall 226 can include at least
one aperture 228. The aperture 228 in the sealing wall 226 can be
configured to couple with a strain relief 230 or other structure
configured to facilitate passing one or more wires through the
sealing wall 226. The strain relief 230 can include one or more
gaskets or other sealing structures configured to facilitate
passing one or more wires or cords 233 through the sealing wall in
a fluid or liquid-tight manner. In some embodiments, the strain
relief 230 is connected to the aperture 228 in the sealing wall 226
via threads, detents, and/or friction fit. In some embodiments, one
or more electrical connectors (e.g., wires) can be inserted through
the one or more electrical ports 212 prior to installation of the
outer housing 202 at an installation site (e.g., in the
ground).
In-Grade Light Inner Housing
[0232] As discussed above, the in-grade light 200 can include an
inner housing assembly 204. The inner housing assembly 204 can be
configured to couple and decouple with the outer housing 202. In
some embodiments, the inner housing assembly 204 is configured to
pass at least partially through the second end 216 of the outer
housing 202 during coupling with and decoupling from the outer
housing 202. FIG. 28 illustrates an example wherein the inner
housing assembly 204 has a first end 234 (e.g., lower end) and a
second end 236 (e.g., upper end).
[0233] The inner housing assembly 204 can be constructed such that,
when assembled, the inner housing assembly 204 hermetically (e.g.,
in an air-tight, or water-tight manner) seals an interior of the
inner housing assembly 204 from an exterior of the inner housing
assembly 204. In some embodiments, the inner housing assembly 204
is constructed such that it remains (e.g., or at least is capable
of remaining) hermetically sealed before, during, and after
installation of the inner housing assembly 204 in the outer housing
202 and/or removal of the inner housing assembly 204 from the outer
housing 202.
[0234] The inner housing assembly 204 can be constructed such that
it remains hermetically sealed before, during, and/or after tilting
of the cartridge and/or rotation of the cartridge 18/inner housing
assembly 204 with respect to the outer housing 202. For example, as
illustrated in FIG. 29, the inner housing 204 (e.g., the inner
housing body 238) can include a mating structure 237. The mating
structure 237 can be, for example, a shoulder, flange, indentation,
protrusion, aperture, and/or some other structure configured to
facilitate mating between the inner housing 204 and the outer
housing 202. In the illustrated embodiment, the mating structure
237 is a shoulder 237 configured to be held (e.g., compresses,
wedged, and/or secured) between the heads of one or more fastener
239 and the outer housing 202 when the one or more fasteners 239
are connected to the outer housing 202. In some embodiments, an
intermediate structure such as a washer can be positioned between
the heads of the fasteners 239 and the mating structure 237 to hold
the mating structure 237. The fasteners 239 can be configured to
mate with one or more outer apertures 312 of the outer housing 202
(e.g., of the connection portion 210 of the outer housing 202).
[0235] In some configurations, the inner housing 204 is configured
to be rotatable (e.g., about the outer housing axis 218) with
respect to the outer housing 202 when the fasteners 239 and/or
other mating structures are loosened. For example, in some
embodiments, loosening of the fasteners 239, with or without
removal of the fasteners 239 from the outer housing 202, permits
rotation of the inner housing 204 with respect to the outer housing
202. Tightening of the fasteners 239 (e.g., such that the mating
structure 237 is held) can facilitate rotational locking of the
inner housing 204 with respect to the outer housing 202. In some
embodiments, the shoulder 237 of the inner housing 204 and
fasteners 239 form a sort of rail system wherein the shoulder 237
rides in the space between the heads of the fasteners 239 an
portion (e.g., the connecting portion 210) of the outer housing
202. The inner housing 204 can be configured to rotate between many
(e.g., infinite) different rotational positions with respect to the
outer housing 202. In some configurations, interference between
structures of the inner and outer housings 204, 202 can limit the
rotational range of motion between the inner and outer housings
204, 202. For example, the outer apertures 310 (described in more
detail below) may be positioned in protrusions 311 extending
radially outward from the shoulder 237. In some cases, the
protrusions 311 interfere with the fasteners 239 during rotation of
the inner housing 204.
[0236] Moving to FIG. 30, the inner housing assembly 204 can
include an inner housing body 238. The inner housing body 238 is
hollow or at least partially hollow and is configured to receive
the cartridge 18. In some embodiments, the inner housing assembly
204 includes a pivot frame 240. The pivot frame 240 can be
configured to couple with one or both of the inner housing body 238
and the cartridge 18. The inner housing assembly 204 can include a
tilting assembly 270 (FIGS. 33-39). The tilting assembly 270 can be
configured to facilitate user control of the tilt angle of the
cartridge 18 and/or pivot frame 240 with respect to the inner
housing body 238 (e.g., and with respect to the outer housing 202),
as is described in more detail below.
[0237] In some embodiments, the inner housing assembly 204 includes
a lens assembly 242. The lens assembly 242 can be configured to
connect to the inner housing body 238 at or near the second end 236
of the inner housing assembly 204. The inner housing assembly 204
can include a strain relief 264 positioned in an aperture of the
inner housing body 238 and configured to facilitate passage of one
or more electrical connectors (e.g., wires) between the interior
and exterior of the inner housing assembly 204. The strain relieve
264 can be the same as or similar to the strain relief 230 in
structure and/or in function. In some embodiments, the strain
relief 264 is configured to permit passage of one or more wires in
a fluid-tight or liquid-tight manner.
Pivot Frame
[0238] As illustrated in FIGS. 30-32, the pivot frame 240 can
include a sleeve portion 244. The sleeve portion 244 can have an
elongate shape such as, for example, a generally cylindrical shape.
The pivot frame 240 can include one or more tilting members 246. In
some embodiments, the pivot frame 240 includes two tilting members
246 connected on opposite sides of the sleeve portion 244. In some
embodiments, the pivot frame 240 (e.g., the sleeve portion 244 of
the pivot frame 240) includes one or more mating features
configured to facilitate removable connection between the sleeve
portion 244 and a cartridge 18.
[0239] The tilting members 246 can be configured to engage with
tilting structure on the inner housing body 238. For example, the
tilting members 246 can be configured to fit at least partially
within tilting pockets 252 in the inner housing body 238. In some
embodiments, the tilting members 246 are configured to rotate
within the pockets 252 between a first tilt position (FIG. 36) and
a second tilt position (FIG. 37). In some embodiments, light from
the cartridge is directed in a direction parallel or substantially
parallel to the outer housing axis 218 when the pivot member 240 is
in the first tilt position.
[0240] The tilting members 246 can include an arcuate surface 248
(FIG. 31). In some embodiments, the tilting members 246 include
stop walls 250 configured to limit the range of tilting of the
pivot frame 240. One or more of the tilting members 246 can include
a plurality of stop walls 250. One or more of the stop walls 250
can be substantially straight in a plane parallel to the axis about
which the pivot frame is configured to tilt. In some embodiments,
each of the tilting members 246 includes at least two stop walls
250 offset from each other by a tilt angle 266 (FIG. 32). The tilt
angle 266 can define the angular distance between the first tilt
position (FIG. 36) and the second tilt position (FIG. 37). In some
embodiments, the tilt angle 266 is at least 5.degree., at least
10.degree., at least 15.degree., at least 25.degree., and/or at
least 45.degree.. In some embodiments, the tilt angle 266 is
approximately 20.degree..
[0241] Referring to FIGS. 33 and 34, the tilting pockets 252 can
have arcuate surfaces 254 configured to engage the arcuate surface
248 of the tilting members 246 and facilitate tilting of the pivot
frame 240 with respect to the inner housing body 238. As
illustrated in FIGS. 34-35, in some embodiments the stop walls 250
are configured to abut a pivot frame retainer 268. The pivot frame
retainer 268 can be, for example, an elongate panel or other
structure connected to the inner housing body 238. In some
embodiments, the pivot frame retainer 268 is removably connected to
the inner housing body 238 via, for example, one or more fasteners.
The pivot frame retainer 268 can spaced from the arcuate surfaces
254 of the tilting pockets 252. In some embodiments the pivot frame
retainer 268 and arcuate surfaces 254 combine to form a bounded or
substantially bounded wall configured to inhibit or prevent
inadvertent removal of the tilting members 246 from the pockets
252. In some embodiments, the pivot frame retainer 268 is integral
with the inner body housing 238. In some embodiments, the pivot
frame retainer 268 could be one or more screws and/or other
fasteners.
[0242] As best shown in FIG. 34, the pivot frame 240 can include an
electrical connection (e.g., plug) 256. The plug 256 can be
configured to connect (e.g., mechanically and/or electrically
connect) to the electrical connector 112 of the cartridge 18. The
sleeve portion 244 can include one or more channels 258 (e.g.,
alignment structures) configured to receive the alignment structure
84 of the cartridge 18. The channels 258 can be configured to
inhibit or prevent misalignment between the cartridge 18 and the
pivot frame 240 before, during, and/or after mating of the
cartridge 18 with the pivot frame 240. In some embodiments, the
pivot frame 240 includes one or more thermally-conductive pads 260
configured to operate in a same or similar manner as the pads 89
described above. As illustrated in FIG. 35, in some embodiments,
the cartridge 18 does not include a lens, diffuser or other optical
structure other than the beam reflector 118. In some embodiments,
the cartridge 18 may not include a beam reflector.
[0243] In some embodiments, the cartridge 18 and pivot frame 240
are configured to couple and decouple in a manner similar to or the
same as the manner described above with respect to the cartridge 18
and light housing 12. For example, as best illustrated in FIG. 31,
the pivot frame 240 can include one or more tab openings 261
configured to receive a locking tab 90 of the cartridge 18. The
pivot frame can include one or more tab slots 263 configured to
function in a manner similar to or the same as the tab slot 92 of
the light housing 12. The tab slot 263 can be in communication with
the tab opening 261 to permit rotation of the collar 74 of the
cartridge 18 within the pivot frame 240 between locked and unlocked
positions. In some embodiments, when the collar 74 is in the locked
position within the pivot frame 240, interference between the tab
90 and the walls of the tab slot 263 inhibits or prevents
inadvertent movement of the cartridge 18 out from the pivot frame
240.
Tilting Assembly
[0244] As illustrated in FIGS. 33-37, the inner housing assembly
204 can include a tilting assembly 270. The tilting assembly 270
can be positioned at least partially within a tilt housing 271 (see
also, FIG. 29) extending outward from the inner housing body 238.
The tilting assembly 270 can be configured to facilitate user
control over the tilt angle of the cartridge 18 with respect to the
inner housing body 238. The tilting assembly 270 can include one or
more user input portions configured to receive user input. The
assembly 270 can include one or more components configured to
translate the user input to tilt the cartridge 18 and/or pivot
frame 240 in one or more directions.
[0245] As best illustrated in FIG. 38, the tilting assembly 270 can
include an adjusting shaft 272. The adjusting shaft 272 can include
a user input portion 274 positioned on a first end of the shaft
272. The user input portion 274 can be, for example, a flat head,
Phillips head, Allen head, or other tool-receiving screw-tip head
configured to receive a tool for rotation of the shaft 272. The
adjusting shaft 272 can include a threaded portion 276 extending
over a portion of the length of the shaft 272 (e.g., extending from
a second end of the shaft toward the first end of the shaft).
[0246] The tilting assembly 270 can include a tilt-transmitting
portion. For example, the tilt-transmitting portion can be a collar
278. The collar 278 can be adjustably connected to the shaft 272.
For example, the collar 278 can include a threaded aperture
configured to engage with the threaded portion 276 of the
adjustment shaft 272. In some embodiments, rotation of the
adjustment shaft 272 moves the collar 278 in a direction parallel
to the rotation axis of the adjustment shaft 272. In some
embodiments, the rotation axis of the adjustment shaft 272 is
parallel or substantially parallel to the outer housing axis 218
when the in-grade light 200 is assembled.
[0247] In some embodiments, the tilting assembly 270 includes a
structure configured to translation motion of the collar 278 to
tilting of the pivot frame 240 and/or of the cartridge 18. For
example, the tilting assembly 270 can include a tilt bracket 280.
The tilt bracket 280 can be connected to (e.g., via fasteners,
welding, co-molding, adhesives, or otherwise) the pivot frame 240
and/or directly to the cartridge 18. The tilt bracket 280 can
include one or more elongated slots 282 or other structure
configured to slidingly engage with a portion of the collar 278.
For example, the collar 278 can include one or more protrusions 284
configured to fit at least partially in the slots 282. In some
embodiments, the protrusions 284 are configured to receive
fasteners to inhibit or prevent inadvertent disconnection between
the collar 278 and the slots 282. In some embodiments, fasteners
are inserted through the slots 282 into the collar 278 and the
fasteners ride within the slots 282.
[0248] Comparing FIGS. 36 and 37, rotation of the adjustment shaft
272 can move the collar 278 along the threaded portion 276 of the
adjustment shaft 272. Movement of the collar 278 toward the lens
assembly 242 (e.g., upward) can tilt the pivot frame 240 in a
clockwise direction in the frame of reference of FIGS. 36 and 37
(e.g., the top end of the pivot frame 240 and cartridge 18 tilt
away from the tilting assembly 270). Movement of the collar away
from lens assembly 242 (e.g., downward) can tilt the pivot frame in
a counterclockwise direction in the frame of reference of FIGS. 36
and 37 (e.g., the top end of the pivot frame and cartridge 18 tilt
toward the tilting assembly 270). Movement of the collar 278
downward can cause the collar 278 to ride in the slots 282 of the
bracket 280 in a direction away from the pivot frame 240. In some
embodiments, movement of the collar 278 upward can cause the collar
278 to ride in the slots 282 of the bracket 280 in a direction
toward from the pivot frame 240. The extent to which the pivot
frame 240 tilts toward and away from the tilting assembly 270 can
be limited by the engagement of the stop walls 250 with the pivot
frame retainers 268, as described above.
[0249] As illustrated in FIGS. 33 and 39, the tilting assembly 270
can include a shaft retainer 286 configured to reduce or eliminate
movement of the shaft 272 in a direction toward the lens assembly
242 before, after, and/or during rotation of the shaft 272. In some
embodiments, the adjustment shaft 272 includes a flange 288 (FIG.
38) or other structure configured to abut the retainer 286 and/or
some other portion of the inner housing assembly 204 to inhibit or
prevent movement of the adjustment shaft 272 parallel to the axis
of rotation of the adjustment shaft.
[0250] FIGS. 38 and 39 illustrate an embodiment of the tilting
assembly 270 that can include one or more sealing structures
configured to inhibit or prevent ingress or liquid or other fluids
into the inner housing assembly 204. For example, the adjustment
shaft 272 can include one or more (e.g., two, three, four, etc.)
grooves 290 configured to engage O-rings 292 or other sealing
structures. The O-rings 292 can be configured to inhibit or prevent
ingress of moisture or other environmental hazards into the inner
housing assembly 204 around the adjustment shaft 272.
[0251] The tilting assembly 270 can be used in combination with
lights other than in-grade lights. For example, the tilting
assembly 270 can be incorporated into and/or used in conjunction
with lights mounted into/on a wall or light post. In some cases,
the tilting mechanism 270 can be used in a subterranean setting
(e.g., under a translucent or transparent walkway). In some cases,
the tilting mechanism 270 be used in submarine settings (e.g., pool
lights, pond lights, etc.). In one or all of the applications of
the tilting mechanism 270, the tilting mechanism 270 is configured
to facilitate tilting or aiming of the light without breaking a
seal of the inner housing assembly and without moving the outer
housing.
Methods of Assembling the In-Grade Light
[0252] Referring now to FIG. 40, the inner housing assembly 204 can
be assembled prior to inserting the inner housing assembly 204 into
the outer housing assembly 202. In some cases, all or a portion of
the inner housing assembly 204 can be disassembled while positioned
in the outer housing 202.
[0253] The pivot frame 240 can be inserted into the inner housing
body 238. The tilting members 246 can be positioned within the
tilting pockets 252 of the body 238. The pivot frame retainers 268
can be installed on the inner housing body 238 to inhibit or
prevent removal of the tilting members 246 from the pockets 252.
The tilting assembly 270 can be connected to the pivot frame 240
and/or to the inner housing body 238 before or after the pivot
frame 240 is positioned within the inner housing body 238.
[0254] The cartridge 18 can be coupled with the pivot frame 240 in
the manner described above. In some embodiments, the cartridge 18
does or does not include a handle 76 and collar 74 as described
above. Coupling of the cartridge 18 with the pivot frame 240 can
electrically connect the cartridge 18 to the pivot frame 240 and/or
to some other portion of the inner housing assembly 204.
[0255] The lens assembly 242 can be installed on the inner housing
body 238 to seal the interior of the inner housing assembly 204.
For example, the lens assembly 242 can be installed on the inner
housing assembly 204 using fasteners, detents, friction fittings,
or other releasable connection methods or structures.
[0256] In some embodiments, the lens assembly 242 includes a lens
seal 296. The lens seal 296 can have an annular shape and can be
sized to engage with a portion of the inner housing body 238. For
example, the lens seal 296 can be configured to engage with a seal
groove 298 in the second end 236 of the inner housing body 238
(FIG. 34). A lens 300 can be positioned between the lens seal 296
and a lens frame 302. The lens frame 302 can be configured to
connect to the second end 236 of the inner housing body 238. For
example, the lens frame 302 can include one or more inner apertures
304 configured to receive fasteners. The one or more inner
apertures 304 can be distributed to align with one or more inner
apertures 306 on the second end 236 of the inner housing body 238.
Fasteners 308 can be inserted through the inner apertures 304, 306
of the lens frame 302 and inner housing body 238 and tightened to
compress the lens seal 296 between the lens 300 and the inner
housing body 238. In some embodiments, the lens frame 302 includes
one or more gaps or spaces 309 (FIG. 40) in its perimeter. The
space 309 can be sized and/or positioned to facilitate user access
to the adjustment shaft 272 after the frame 302 is connected to the
inner housing body 238.
[0257] As best illustrated in FIG. 41, a method of assembling the
overall in-grade light 200 can include inserting the internal cap
assembly 220 into the outer housing 202. For example, the internal
cap assembly 220 can be inserted at least partially into the first
segment 208a of the sleeve portion 208 of the outer housing 202.
The lens frame 302 and/or inner housing body 238 can include one or
more connection structures configured to facilitate connection
between the inner housing 204 and the outer housing 202. For
example, as described above, the inner housing body 238 can include
a shoulder 237 or other mating structure configured to engage with
the fasteners 239 when the fasteners 239 are inserted into the
outer apertures 312 of the outer housing 202.
[0258] Optionally, cover 206 can be connected to one or both of the
inner and outer housings 202, 204. For example, the cover 206 can
include one or more apertures 316 configured to align with the
outer apertures 310, 312 of one or both of the inner and outer
housings 202, 204. In some embodiments, the fasteners 314 can be
inserted through the cover 206, and the inner housing 204 to
connect the cover 206 to the inner housing 204. In some
embodiments, the cover 206 can be connected directly or indirectly
(e.g., through inner housing 204) with the outer housing 202 using
one or more fasteners. The cover 206 can be decorative to match a
color scheme of the installation site. The cover 206 may include
various features such as a ring, a cowling, fins, spokes, a full
cover with optics, and/or other ornamental or function features. In
some embodiment, the cover 206 "hides" or covers the fasteners 308
when installed on the in-grade light 200. In some embodiments, the
cover 206 covers the adjustment shaft 272 (e.g., the user input
portion 274 of the adjustment shaft 272).
[0259] To remove the inner housing 204 from the outer housing 202,
the user may disconnect the fasteners 239 from the inner and/or
outer housings 202, 204 and lift the inner housing 204 from the
outer housing 202. In some embodiments, one or more electrical
connections (e.g., plugs or other connections) between the inner
housing 202 and some other portion of the in-grade light 200 can be
disconnected to completely remove the inner housing 204 from the
in-grade light 200. Each of the steps of inserting and removing the
inner housing 204 from the outer housing 202 can be performed
without unsealing the inner housing 204. In some embodiments, the
cover 206 may be removed before or after removing the inner housing
204 from the outer housing 202.
[0260] To adjust the tilt of the pivot frame, a user can remove the
cover 206, if present. If no cover 206 is used, the user may use a
tool to rotate the adjustment shaft 272 of the tilt assembly 270.
This adjustment to the tilt of the pivot frame 240 and/or cartridge
18 can be performed without unsealing the inner housing 204. In
some cases, a user can rotate the entire inner housing 204 with
respect to the outer housing 202 (e.g., about an axis or rotation
parallel or substantially parallel to the outer housing axis 218)
by first loosening or removing the fasteners 239. Upon loosening or
removing of the fasteners 239, the user can rotate the inner
housing 204 to different desired rotational position. The tilt
housing 271 can rotate freely within the third segment 208c of the
sleeve portion 208 of the outer housing 202 during rotation of the
inner housing 204. Rotation of the inner housing 204 as described
above can be performed without unsealing the inner housing 204.
[0261] Installing, removing, and adjusting the position of the
inner housing 204 and/or its components without unsealing the inner
housing 204 can greatly improve the performance of the in-grade
light 200. The electrical components of the inner housing 204
(e.g., the cartridge 18 and its subcomponents) can be isolated from
the surrounding environment and its hazards. Any repair and
replacement of the components of the inner housing 204 can be
performed in a controlled environment away from the installation
site of the in-grade light 200. In some cases, replacement inner
housings 204 can be swapped with existing inner housings 204
without the need for the installer to open any of the inner
housings 204.
Methods of Installing the In-Grade Light
[0262] In some applications, the outer housing 202 may first be
installed before other components of the in-grade light 200 are
assembled. For example, in a landscaping or walkway application, it
may be desirable to install the outer housing 202 in the ground
before assembling the remaining in-grade light components.
Installing the outer housing 202 in concrete or other materials may
present challenges, as it may be difficult to properly chair (e.g.,
align) the upper end of the outer housing 202 with the surface of
the walkway or other installation site.
[0263] FIGS. 42-44 illustrate a method of installing the outer
housing 202 and associated installation structures. As illustrated,
the installation structures can include an installation cap 320.
The installation cap 320 can include a cover portion 321 having a
generally planar shape. In some embodiments, the cover portion 321
is sized to cover all or substantially all of the upper end and/or
connection portion 210 of the outer housing 202. The cover portion
321 can include one or more apertures 322 configured to align with
the outer apertures 312 of the outer housing 202. Fasteners 324 can
be inserted through apertures 322 into the outer apertures 312 of
the outer housing 202 to connect the installation cap 320 to the
outer housing 202. In some embodiments, other connection methods
and structures (e.g., detents, friction fittings, threading, etc.)
are used in addition to or instead of the fasteners 324.
[0264] The installation cap 320 can include one or more upward
walls 326 extending from the cover portion 321. The upward walls
326 can be structurally supported by one or more ribs 328 extending
between the upward walls 326 and the cover portion 321. The upward
walls 326 can include one or more apertures 330 configured to
facilitate connection of the upward walls 326 to a chairing
structure 332 (e.g., a wood beam).
[0265] As illustrated in FIG. 44, the chairing structure 332 can be
braced and/or supported by one or more supports 334 (e.g., blocks,
beams, or other structures). The outer housing 202 can be suspended
in the installation site using the installation cap 320 and
structures 332, 334. Concrete, dirt, clay, or other materials can
be filled in around the outer housing 202 to reduce the likelihood
that the upper end of the in-grade light 200 is misaligned with the
surface of the finished walkway or other installation feature. Upon
pouring and/or setting of the concrete/dirt, the installation cap
320 can be removed and the other components of the in-grade light
200 can be installed. In some cases, the cover portion 321 may have
at least one width greater than the diameter of the outer housing
202. In some embodiments, an outer width or diameter of the cover
portion 321 is slightly larger than the outer diameter of the cover
206 to facilitate flush installation of the cover 206 with the
surface of the concrete or other material surrounding the outer
housing 202.
[0266] In some embodiments, wires and/or other electrical
connection structures can be connected to the outer housing 202
prior to pouring of the concrete/dirt. For example, wiring can be
inserted through the one or more electrical ports 212 and the
strain relief 230.
[0267] For expository purposes, the term "horizontal" as used
herein is defined as a plane parallel to the plane or surface of
the floor of the area in which the system being described is used
or the method being described is performed, regardless of its
orientation. The term "floor" floor can be interchanged with the
term "ground." The term "vertical" refers to a direction
perpendicular to the horizontal as just defined. Terms such as
"above," "below," "bottom," "top," "side," "higher," "lower,"
"upper," "over," and "under," are defined with respect to the
horizontal plane.
[0268] As used herein, the terms "attached," "connected," "mated,"
and other such relational terms should be construed, unless
otherwise noted, to include removable, moveable, fixed, adjustable,
and/or releasable connections or attachments. The
connections/attachments can include direct connections and/or
connections having intermediate structure between the two
components discussed.
[0269] The terms "approximately", "about", "generally" and
"substantially" as used herein represent an amount close to the
stated amount that still performs a desired function or achieves a
desired result. For example, the terms "approximately", "about",
"generally," and "substantially" may refer to an amount that is
within less than 10% of the stated amount.
* * * * *